Support Structure System And Method For Manufacturing and Using the Same

Description

STATEMENT OF RELATED APPLICATION(S)

This application is a continuation-in-part of U.S. patent application Ser. No. 18/944,207, entitled “Support Structure and Method for Manufacturing Thereof”, filed Nov. 12, 2024, which is a continuation-in-part of U.S. patent application Ser. No. 18/677,847, entitled “Support Structure and Method for Manufacturing Thereof”, filed May 29, 2024, the disclosures of which are hereby incorporated by reference herein in their entirety.

TECHNICAL FIELD

The present invention relates to the field of handrail support structures, particularly to the handrail support structures and methods of repairing said structures.

BACKGROUND

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 embedded in concrete have been rotting out for decades. Although handrails embedded 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 for some homeowner insurance policies, safe and structurally sound handrails are required; and repairs are required to be completed within a short deadline. As such, finding affordable, easy, and quick solutions for needed 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 into the cement 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 quite common to see handrails rusted at the bottom.

Traditional repair methods involve removing and replacing the rusted railing components, and are time consuming and labor intensive. In more recent years, the development of repair feet has proven to be a cost-effective alternative to complete replacement. Repair feet eliminate the need to core drill a railing back into the concrete, thereby avoiding any further damage caused by concrete-induced corrosion. Further, repair feet eliminate a need to weld for repairing the handrails, since once an adhesive is added into the repair feet, they become waterproof as well. Existing repair feet, however, are primarily designed for use with larger structures (such as wooden telephone poles) and are unsuitable for use with smaller diameter, metal railings. Additionally, existing repair feet are also formed of thin, flimsy tin pieces (aimed at wooden poles) or are formed of brittle cast iron which often crack during installation.

Therefore, a need exists for a metal railing repair system that reduces repair labor, can be installed retroactively on the scale of a hand railing, and will protect the repaired railing from further concrete corrosion.

SUMMARY

In a first aspect of the invention, according to a first embodiment, a support structure system for repairing a handrail post includes a first support body and a second support body each including a base plate, a base wall, and two side walls; at least two fasteners configured to secure the first support body and the second support body to the handrail post; and a plurality of base fasteners configured to secure the support structure system to a ground surface, wherein for each of the first support body and the second support body, the base plate is orthogonal to the base wall and the two side walls, the base wall is orthogonal to the two side walls, and the two side walls are parallel to each other, for each of the first support body and the second support body, the base wall and the two side walls define a channel therebetween, the channel of the first support body is dimensioned to receive at least a portion of the handrail post therein, and the channel of the second support body is dimensioned to receive the first support body therein.

In another aspect, the base plate of each of the first support body and the second support body includes at least two holes configured to receive a corresponding one base fastener of the plurality of base fasteners.

In another aspect, a number of base fasteners in the plurality of base fasteners corresponds to a number of holes in the base plate of both the first support body and the second support body.

In another aspect, for each of the first support body and the second support body, the base plate delimits one end of the channel.

In another aspect, further including a base plate leading edge on each base plate of the first support body and the second support body, wherein the base plate leading edge of the first support body is configured to contact the base plate leading edge of the second support body when the second support body receives the first support body.

In another aspect, wherein a first fastener of the at least two fasteners is configured to pass through a first side wall of the two side walls of the second support body, through a first side wall of the two sidewalls of the first support body, and through at least a portion of the handrail post on a first side of the handrail post, a second fastener of the at least two fasteners is configured to pass through a second side wall of the two side walls of the second support body, through a second side wall of the two sidewalls of the first support body, and through at least a portion of the handrail post on a second side of the handrail post, and the first side of the handrail post is opposed to the second side of the handrail post.

In a second aspect of the invention, according to a second embodiment, a method of repairing a handrail post using a support structure system includes preparing the handrail post; applying a bonding agent to interior surfaces of a first support body, wherein the first support body comprises a base plate, a base wall, and two side walls, the base wall and two sidewalls forming a channel therebetween; assembling the first support body on the handrail post such that the handrail post is at least partially received within the channel of the first support body; applying the bonding agent to interior surfaces of a second support body, wherein the second support body comprises a base plate, a base wall, and two side walls, the base wall and two sidewalls forming a channel therebetween; assembling the second support body on the handrail post and first support body such that the handrail post and first support body are at least partially received within the channel of the second body; securing at least two fasteners through the first support body, the second support body, and the handrail post; and inserting a plurality of base fasteners through the base plate of each of the first support body and the second support body into a ground surface.

In another aspect, preparing the handrail post further includes cutting the handrail post in the proximity of the ground surface, such that a gap between a bottom of the handrail post and the ground surface is at least equal to a thickness of the base plate of each of the first support body and the second support body.

In another aspect, the at least two fasteners are self-tapping metal screws.

In another aspect, the plurality of base fasteners are concrete screws.

In another aspect, securing at least two fasteners further includes a first fastener of the at least two fasteners is configured to pass through a first side wall of the two side walls of the second support body, through a first side wall of the two sidewalls of the first support body, and through at least a portion of the handrail post on a first side of the handrail post, a second fastener of the at least two fasteners is configured to pass through a second side wall of the two side walls of the second support body, through a second side wall of the two sidewalls of the first support body, and through at least a portion of the handrail post on a second side of the handrail post, and the first side of the handrail post is opposed to the second side of the handrail post.

In another aspect, each base plate of the first support body and the second support body comprises at least two holes extending therethrough, the at least two holes configured to receive a base fastener of the plurality of base fasteners, and a number of base fasteners in the plurality of base fasteners corresponds to the number of holes in both base plates of the first support body and the second support body, such that each hole has a corresponding one base fastener.

In another aspect, any one or more aspects or features described herein may be combined with any one or more other aspects or features for additional advantage.

Other aspects and embodiments will be apparent from the detailed description and accompanying drawings.

Those skilled in the art will appreciate the scope of the present disclosure and realize additional aspects thereof after reading the following detailed description of the preferred embodiments in association with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.

FIG. 1 is a bottom perspective view of first and second support bodies of a support structure system according to a first embodiment of the present invention.

FIG. 2 is a top perspective view of the first and second support bodies of the support structure system of FIG. 1.

FIG. 3 is a perspective view of the first and second support bodies, shown in an assembled position, of the support structure system of FIG. 1.

FIG. 4 is a perspective view of a first support body, shown assembled on a handrail post, of the support structure system of FIG. 1.

FIG. 5 is a perspective view of the support structure system of FIG. 1, shown assembled on the handrail post.

FIG. 6 is a flow diagram of a method of forming the support structure system of FIG. 1.

FIG. 7 is a flow diagram of a method of repairing the handrail post using the support structure system of FIG. 1.

DETAILED DESCRIPTION

The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the embodiments and illustrate the best mode of practicing the embodiments. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the disclosure and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the present disclosure. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It will be understood that when an element such as a layer, region, or substrate is referred to as being “on” or extending “onto” another element, it can be directly on or extend directly onto the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or extending “directly onto” another element, there are no intervening elements present. Likewise, it will be understood that when an element such as a layer, region, or substrate is referred to as being “over” or extending “over” another element, it can be directly over or extend directly over the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly over” or extending “directly over” another element, there are no intervening elements present. It will also be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.

Relative terms such as “below” or “above” or “upper” or “lower” or “horizontal” or “vertical” may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including” when used herein specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Referring now to FIGS. 1-5, the support structure system 100 of the present invention comprises a first support body 102 and a second support body 104. In an exemplary embodiment, the first support body 102 and the second support body 104 are substantially similar in shape. In a further exemplary embodiment, the first support body 102 is dimension such that at least a part of the first support body 102 is configured to be at least partially enclosed within a portion of the second support body 104 (see FIG. 3). The first support body 102 and the second support body 104 are further dimensioned in order to receive at least a portion of a handrail post 900 therein (see FIGS. 4 and 5).

Each of the first support body 102 and the second support body 104 comprises a base plate 106, a base wall 108, and at least two side walls 110. In an exemplary embodiment, the base plate 106 is substantially orthogonal to the base wall 108 and the at least two side walls 110. Each base plate 106 further comprises at least two holes 112 extending through the base plate 106, which are configured to receive a fastener therethrough. Each base plate 106 further comprises a base plate leading edge 114. In an exemplary embodiment, the base plate leading edge 114 of the first support body 102 is configured to contact the base plate leading edge 114 of the second support body 104 when the support structure system 100 is assembled.

In an exemplary embodiment, the base wall 108 is configured to be substantially orthogonal to each side wall of the at least two side walls 110, where the at least two side walls 110 are configured to be substantially parallel to each other. The base wall 108 and the at least two side walls 110 are configured to form a channel 116 having a channel width equal to the spacing between the at least two side walls 110. In an exemplary embodiment, the channel width of the channel 116 of the first support body 102 is dimensioned so as to equal or slightly exceed an outer dimension of the handrail post 900. The channel width of the channel 116 of the first support body 102 may be 1.27 cm (0.5 in.), 1.59 cm (0.625 in.), 1.91 cm (0.75 in.), 2.22 cm (0.875 in.), 2.54 cm (1 in.), 2.86 cm (1.125 in.), 3.18 cm (1.25 in.), 3.49 cm (1.375 in.), 3.81 cm (1.5 in.), 4.45 cm (1.75 in.), 5.08 cm (2 in.), 5.72 cm (2.25 in.), 6.35 cm (2.5 in.), and/or any other suitable width dimension. In a preferred embodiment, the channel width of the channel 116 of the first support body 102 is 2.86 cm (1.125 in.).

In an exemplary embodiment, each of the first support body 102 and the second support body 104 comprises an outer dimension. The outer dimension is equal to the channel width plus twice a thickness of a side wall 110 of the at least two side walls 110. In an exemplary embodiment, the channel width of the channel 116 of the second support body 104 is substantially the same as or slightly larger than the outer dimension of the first support body 102 (see FIG. 3).

In an exemplary embodiment, when the handrail post 900 has been received within the first support body 102 and the first support body 102 has been received within the second support body 104, at least two fasteners 118 are utilized to provide secure engagement between the support structure system 100 and the handrail post 900 (see FIG. 5). At least one first side fastener 118 of the at least two fasteners 118 is configured to be inserted through one side wall 110 of the at least two side walls 110 of the second support body 104 and one side wall 110 of the at least two side walls 110 of the first support body 102 on a first side of the handrail post 900. The at least one first side fastener 118 is further configured to engage at least a portion the handrail post 900. In a preferred embodiment, the at least two fasteners 118 are self-tapping metal screws which are configured to be screwed through the at least two side walls 110 into the handrail post 900. When the at least one first side fastener 118 comprises two or more first side fasteners 118, each first side fastener 118 is spaced apart from each other first side fastener 118. At least one second side fastener 118 of the at least two fasteners 118 is configured to be inserted through an other side wall 110 of the at least two side walls 110 of the second support body 104 and an other side wall 110 of the first support body 102 on a second side of the handrail post 900, wherein the second side is opposed to the first side of the handrail post 900. The at least one second side fastener 118 is further configured to engage at least a portion the handrail post 900. When the at least one second side fastener 118 comprises two or more second side fasteners 118, each second side fastener 118 is spaced apart from each other second side fastener 118.

Referring now to FIG. 6, a flow diagram of a method 200 of forming the support structure system 100 of the present invention are shown. In step 202, a sheet of metal is provided to form the first support body 102. The sheet of metal is dimensioned to the size of the base wall 108 and the at least two side walls 110. In step 204, the sheet of metal is bent a first time, such that a first side wall 110 of the at least two side walls 110 is substantially orthogonal to the base wall 108. In step 206, the sheet of metal is bent a second time, such that the second side wall 110 of the at least two side walls 110 is substantially orthogonal to the base wall 108. In step 208, the base plate 106 is prepared by drilling the at least two holes 112 therethrough. In step 210, the base plate 106 is secured to the base wall 108 and the at least two side walls 110. In an exemplary embodiment, the base plate 106 may be adhered to, screwed to, nailed to, welded to, bolted to, and/or secured by any other suitable fastening method. In a preferred embodiment, the base plate 106 is welded to the base wall 108 and the at least two side walls 110. Once the first support body 102 has been completed, the steps of the method 200 are repeated to form the second support body 104.

Referring now to FIG. 7, a flow diagram of a method 300 of repairing the handrail post 900 is shown. In step 302, a user first prepares the handrail post 900 to receive the support structure. The user cuts a bottom of the handrail post 900 away from the concrete where rust or other degradation has occurred. The gap between the bottom of the handrail post 900 and the concrete is configured to be at least slightly larger than a thickness of the base plate 106 of each of the first support body 102 and the second support body 104. In step 304, the user applies a bonding agent to all interior surfaces of the channel 116 of the first support body 102 as well as the surface of the base plate 106 of the first support body 102 facing the channel 116. In an exemplary embodiment, the bonding agent is an epoxy, a glue, and/or any other suitable bonding agent. Examples of commercially available bonding agents include, but are not limited to, epoxy JB weld, 3M® Epoxy adhesive, Loctite®, E6000, Heavy Duty Gorilla Glue®, and weld bond polyvinyl. In step 306, the user assembles the first support body 102 about the bottom of the handrail post 900. The first support body 102 is dimensioned so as to snugly receive the handrail post 900 therein. In an exemplary embodiment, the handrail post 900 is configured to be in contact with the base wall 108 and both side walls 110 of the at least two side walls 110. Additionally, the bottom of the handrail post 900 is configured so as to rest on or adjacent to the base plate 106 of the first support body 102.

In step 308, the user applies the bonding agent to all interior surfaces of the channel 116 of the second support body 104 as well as the surface of the base plate 106 of the second support body 104 facing the channel 116. In step 310, the user assembles the second support body 104 about the bottom of the handrail post 900 and over the first support body 102. The second support body 104 is dimensioned so as to snugly receive the first support body 102 therein. In an exemplary embodiment, the handrail post 900 is configured to be in contact with the base wall 108 and both side walls 110 of the at least two side walls 110. Additionally, the bottom of the handrail post 900 is configured so as to rest on or adjacent to the base plate 106 of the second support body 104. When the support structure system 100 is assembled, in an exemplary embodiment, the base plate leading edge 114 of each of the first support body 102 and the second support body 104 are configured to be in contact with each other.

In step 312, the at least two fasteners 118 are secured through the first support body 102, the second support body 104, and the handrail post 900. In an exemplary embodiment, the number of fasteners in the at least two fasteners 118 may be one, two, three, four, or n fasteners. In a preferred embodiment, the number of fasteners 118 is an even number. In step 314, a plurality of base fasteners 120 are inserted, such that one base fastener 120 of the plurality of base fasteners 120 is inserted into a single corresponding hole 112 of the at least two holes 112 of each base plate 106 of each of the first support body 102 and the second support body 104. In an exemplary embodiment, the number of the base fasteners 120 in the plurality of base fasteners 120 is equal to the number of holes 112 of the first support body 102 and the second support body 104. In a preferred embodiment, the plurality of base fasteners are concrete screws or concrete anchors.

Those skilled in the art will recognize improvements and modifications to the preferred embodiments of the present disclosure. All such improvements and modifications are considered within the scope of the concepts disclosed herein and the claims that follow.