AU2007100433A4 - Rail and post assembly - Google Patents

Description

Regulation 3.2 Revised 2/98

AUSTRALIA

Patents Act, 1990 COMPLETE INNOVATION SPECIFICATION NAME OF APPLICANT ACTUAL INVENTOR ADDRESS FOR SERVICE INVENTION TITLE: DETAILS OF ASSOCIATED PROVISIONAL APPLICATION NO: Joe's Wrought Iron Aluminium Pty Ltd (ACN 088 206 526) Joe Punturiero Peter Maxwell and Associates Level 6 Pitt Street SYDNEY NSW 2000 RAIL AND POST ASSEMBLY 2007 902 571 9 May 2007 Australia The following statement is a full description of this invention including the best method of performing it known to us:m:\docs\20071013\120761 .doc RAIL AND POST ASSEMBLY FIELD OF THE INVENTION This invention relates to the design, manufacture and assembly of balustrades, and more particularly to the connection of vertical post members to horizontal rail members. While the invention will be described hereafter by reference to connecting rails to a post to form a balustrade, it should be noted that the invention is not necessarily limited to this particular field of use.

BACKGROUND TO THE INVENTION A balustrade structure normally consists of a series of vertical post members connected to one or more horizontal rail members. It is common for there to be two horizontal rail members attached to the posts and for there to be a series of smaller vertical members secured into place between the two horizontal rail members. In recent times it has become common to place a sheet of glass in between the two horizontal rail members.

There are a number of problems currently associated with both the attachment of the rails to the posts and the use of glass in between the rails.

The first problem is that the connection made between the rail and the post needs to be both secure and aesthetically pleasing. In the past these requirements have resulted in rails being welded to posts at their interface, usually around the outside or exterior of the rail. However welding generally leaves large unsightly lugs of weld metal at the junction, such that at present the lugs need to be filed off or otherwise finished so that the overall visual appearance is acceptable. This process is laborious, time consuming, and ultimately unsatisfactory as some weld metal will need to remain exterior to the interface between rail and post in order to hold them together. Thus it is not 21/05/07 possible using this method to create an aesthetically pleasing rail and post assembly.

Attempts have been made to overcome this problem in the past. In particular, rail members, which are usually formed in the shape of an open channel, have been welded to posts at the interface of it and the post's surface at a point internal to the channel. In this way there is no unsightly weld visible from above the balustrade assembly as it is concealed inside and underneath the rail.

However this method also introduces its own problem. In particular the internal welding lugs present inside the channel, adjacent to the post, prevents materials such as glass sheets from being introduced into the space between the rails in a way where they abut the post. This is because the weld left in the channel adjacent to the post reduces the depth of the channel at that position, causing glass to crack if it is pushed up into the channel and against the post.

The effect of this is that a gap must be placed between the post and the sheet of material, normally glass, so that the sheet of material does not come into contact with the welding lugs.

It is therefore an object of the present invention to overcome or substantially ameliorate one or more of the problems stated above.

SUMMARY OF THE INVENTION According to one aspect of the invention there is provided a balustrade assembly including a first frame member and second frame member, said first frame member including a channel, said second frame member comprising at least one wall defining a void, wherein the first end of the first frame member is secured to the second frame member in the void of the second frame member.

21/05/07 Preferably the at least one wall of the second frame member further comprises an inclined portion adjacent the aperture and extending into the void, wherein the first end of the first frame member is secured to the inclined portion of the second frame member in the void of the second frame member.

Preferably, the inclined portion is welded to at least one inside portion of the channel.

In an alternate embodiment of the invention, the inclined portion of the second frame member secured to the first end of the first frame member, by acting as a stop for preventing removal of the first end from within the void wherein the first frame member has a screw inserted into the first end of the first frame member after its insertion into the void of the second frame member.

Preferably, the screw passes through the inclined portion into the first end of the first frame member.

In an alternate embodiment of the invention, the first end of the first frame member is secured to the second frame member through the application of at least one spot weld at a point inside the second frame member void.

Preferably the spot weld is located at the interface between the second frame member and a point of the first end of the first frame member where the introduction of a welding lug would not interfere with the placement of a sheet of glass in a position within the first frame member and abutting the second frame member.

In an alternate embodiment of the invention the second frame member further comprises a second aperture in a second wall of second frame member for accessing the void containing the first frame member and for securing the first end of the first frame member to the second frame member.

Preferably the first end of the first end of the first frame member is secured to the second frame member through the second aperture via a weld.

21/05/07 BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of a balustrade assembly featuring vertical rails; Fig. 2 is a perspective view of a balustrade assembly featuring a glass panel; Fig. 3 is a perspective view of a extruded rail channel; Fig. 4 is a perspective view of a post member with a depressed portion according to one aspect of the invention; Fig. 5 is a perspective view of a rail and post assembly according to one aspect of the invention; Fig. 6 is a perspective view showing the underside of a rail and post assembly according to one aspect of the invention; Fig. 7 is a perspective view of a rail and post members pre insertion according to one aspect of the invention; Fig. 8 is a top plan view of a rail and post assembly depicting the location of the welds according to one aspect of the invention; Fig. 9 is a is a side plan view of a rail and post assembly depicting the location of the welds according to one aspect of the invention in which the rail and post are secured at both sides of the post; Fig. 10 is a top plan view of a rail and post assembly depicting the location of the welds according to one aspect of the invention in which the rail and post are secured at both sides of the post; Fig. 11 is a perspective view of a rail and post assembly according to further embodiments of the invention; Fig. 12 is a side plan view of a rail and post assembly according to further embodiments of the invention; Fig. 13 is a top plan view a rail and post assembly according to further 21/05/07 embodiments of the invention; Fig. 14 is a perspective view of a rail and post assembly according to a further embodiment of the invention; Fig. 15 is a side plan view of a rail and post assembly according to a further embodiment of the invention; Fig. 16 is a top plan view a rail and post assembly according to a further embodiment of the invention; Fig. 17 is a perspective view of a rail and post assembly according to a further embodiment of the invention.

Fig. 18 is a perspective view of a rail and post assembly according to another embodiment of the invention.

Fig. 19 is a perspective view of a rail and post assembly according to a further embodiment of the invention.

DETAILED DESCRIPTION Fig. 1 depicts a balustrade assembly according to a traditional design. It has vertical posts 10, horizontal rails 20, and vertical rails 30. Fig. 2 depicts a balustrade assembly that features vertical posts 10, horizontal rails, 20 and glass 40 in place of vertical rails 30. The posts and rails are preferably made out of extruded aluminium, but they may also be made out of other materials such as iron or plastic and may be formed in ways other than extrusion.

The balustrade assembly according to the present invention has been described in its most common form, that is vertical posts and horizontal rail members. However, the person skilled in the art will appreciate that alternate embodiments of the invention are contemplated where the configuration may be different in terms of orientation and angles and that these alternate orientations would still be encompassed by the present invention.

21/05/07 Referring to Fig. 3 the horizontal rail members 20 are formed in the shape such that it features on one side, an open channel 50. This channel is used to hold in place the sheet of glass 40, or vertical rails 30 that are situated between the horizontal rails Fig. 4 depicts a post 10, formed in accordance with one embodiment of the invention. The post 10, in Fig. 4 features 4 walls, 60 and an aperture through which the end of rail member 20 is inserted. The aperture is formed in essentially the same shape as the profile of the rail member 20 such that there are no significant gaps or spaces formed between the rail member 20 and vertical post 10 after the rail member 20 has been inserted. The aperture can be formed by cutting or punching. Preferably the aperture is formed by punching. The post 10 further comprises, in one embodiment of the invention, an inclined portion 80 of the wall 60 which extends into the aperture 70. This inclined portion of the wall is formed in a shape that permits the end of rail member 20 to enter into the void 90, of the post 10, unimpeded. The void extends throughout the post and is open at both ends to facilitate access to the interior of the void 90. The present invention is being described by reference to a four wall post, however the invention is equally applicable to other posts having differing numbers of walls at various angles, including those featuring one continuous wall in the case of circular or oval posts Fig. 5 depicts the rail 20 and post 10 in its assembled form with the open channel 50 being shown. Fig. 6 depicts the rail 20 and post 10 in its assembled form with the exterior of the rail 20 depicted.

Fig. 7 depicts the manner in which rail 20 and post 10 come together.

Fig. 8 depicts a top plan view of the assembled rail, 20, post, 10 and glass As can be seen, the glass 40 abuts wall 60 of post 10. The rail 20 and post are secured by means of welds 100 which join inclined portion 80 with the 21/05/07 inside of the rail 20. As welding involves the melting of metal, the welds are formed in the shape of a lump. These lumps, if present on the glass side of wall would cause the glass to crack or become unseated. By pressing the portion of the wall 60 into the void 90 to form the inclined portion 80 and welding the two members in place at a point inside the void 90 this problem is eliminated. Further, as the welding is conducted inside the void, and as there is little or no gap around the rail 20 once inserted into post 10, the finished product is aesthetically pleasing.

The specific site of the welding can be varied depending on the shape of the aperture 70, inclined portion 80 and the rail 20 inserted. However it is preferable that the welds 100 are located at points 110, 120 and 130 as depicted in Fig. 7. If the inclined portion 80 is punched into a up side down T shape the welds 100 could join point 140 with the inclined portion 80. Figs. 9 and 10 show the side plan and top plan views respectively of a rail and post assembly where there are two inclined portions 80, located at either side of post 10. In this configuration, identical apertures 70 are punched on opposite sides of the post 10 and the rail 20, passed straight through the post Whilst specific mention has been made to welding the two members together, it will be appreciated that alternate means to join two members together including epoxies and resins would also come within the scope of the present invention.

In an alternate embodiment of the invention, the inclined portion 80 is used together with one or more screws to hold the rail 20 in place within the post 10. Fig. 11 depicts a rail 20 and post 10 assembly and screw 150. As can be seen in Fig. 11 the screw 150 pierces the rail at point 170. The inclined portion 80 can be used in two ways to secure the rail 20 within post 10. In one embodiment of the invention, depicted in Figs. 12 and 13, the screw is inserted 21/05/07 adjacent to but inside of the inclined portion 80 at point 170. In this configuration the screw does not pass through the inclined portion 80 which acts as a stop to prevent the rail 20 from being removed from the post in the direction of the inclined portion 80. The assembly according to this embodiment of the invention does provide for a degree of movement within the void 90 of post 10 unless a similarly inserted screw is placed at the opposite end of the post 10 (not depicted).

Alternatively the screw 180 can be made to pass through rail 20 and then through inclined portion 80 at point 160 as depicted in Figs. 12 and 13. In this way a much more secure connection is made which obviates the need to connect the rail 20 with the post 10 at both sides of the post In the case of the rail 20 being inserted into post 10 in the opposite orientation as depicted in Fig. 14, it is still possible to use the screw 170 to secure rail 20 to post 10. As depicted in Figs. 15 and 16, the screws 170 first pass through inclined portion 80 before passing through rail member 20 at point 180.

In an alternate embodiment of the invention, depicted in Fig. 17, the securement of rail 20 with post 10 can be facilitated by the making of a second aperture 190 in post 10. In this position, aperture 190 can be used to access the inserted end of rail 10 whereby the rail 20 can be secured to post through the application of a spot weld, rivet or screw. Any unsightly welding lugs or protrusions from the aperture 190 can be filed down to achieve a flush and aesthetically pleasing finish.

In a further embodiment of the invention, rail 20 and post 10 can be secured together through the application of a spot weld to the internal interface of the inserted end of the rail 20 and post 10 that is accessible from the void In the case of the inserted rail being orientated channel 50 side up, as depicted 21/05/07 in Figure 18, the spot weld can be located at position 200, being the interface of the rail 20 with post 10. The rail 20 and post 10 could also be welded at various other positions on the internal interface between rail 20 and post 10 (not shown) however it is preferable that the weld occur at either one or both positions marked 200 as weld lugs at this position will not interfere with the insertion of glass panels in channel 50. In the case of the rail 20 being inserted in an opposite orientation, as depicted in Figure 19, the spot weld can be made at point 210, or any point at the internal interface of rail 20 and post Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention can be embodied in other forms, which are incorporated herein.

21/05/07

Claims (4)

1. A balustrade assembly including a first frame member and second frame member, said first frame member including a channel, said second frame member comprising at least a wall defining a central void and further comprising an aperture through a first wall for receiving a first end of said first frame member, wherein the first end of the first frame member is secured to the second frame member within the void of the second frame member.

2. The balustrade assembly of claim 1 further comprising an inclined portion of the first wall adjacent the aperture and extending into the void wherein the first end of the first member is secured to the inclined portion of the second member.

3. The balustrade assembly of claim 1 wherein the inclined portion of the second frame member is secured to the first end of the first frame member, through the insertion of a screw into the first end of the first frame member after its insertion into the void of the second frame member.

4. The balustrade assembly of claim 1 wherein the second frame member is secured to the first end of the first member through the application of at least one spot weld at the interface between the wall and the first end of the first frame member. The balustrade assembly of claim 1 wherein the second frame member further comprises a second aperture, through a second wall for accessing the 12 first end of the first frame member, and where the second frame member is secured to the first end of the first frame member through the second aperture. Dated this 21 day of May 2007 Joe's Wrought Iron and Aluminium Pty Ltd Patent Attorneys for the Applicant PETER MAXWELL AND ASSOCIATES