GB2449666A - Handrail connector - Google Patents

Abstract

A connector 62 for securing two rails 6 together, the connector 62 comprising two parts (62a, 62b) pivotably connected together and stepwise adjustment means, each part (62a, 62b) comprising a receiving portion (625a, 625b), for receiving an end of an elongate member 6, the stepwise adjustment means being adapted to limit relative movement of the parts (62a, 62b) at predetermined relative angles for facilitating assembly of a handrail 1 incorporating the connector 62. The adjustment means may be provided by cooperating outer surfaces of the receiving portions. One or each of the parts may comprise a support portion for securing the connector to an upright post. Also independently claimed are a connector for connecting a baluster to a rail and a connector for connecting two posts together.

Description

I

HANDRAILS

The present invention relates generally to handrails, for example handrails for decking.

More specifically, the invention relates to handrail components and methods of assembling the components into a handrail assembly.

Handrail assemblies generally include one or more newel posts, a base rail or support rail, a handrail which runs parallel to the base rail and a plurality of posts which extend therebetween called balusters. It is also known to provide two upper rails for handrail assemblies used on elevated decks in order to provide additional strength and safety and/or for aesthetic purposes.

S * . * SI.

*:::: 15 Generally, the balusters are first secured to the rails, for example using screws. The rail : * and baluster assembly is then mounted to the newel posts directly, for example using S...

screws. The spacing between the deck and the lower rail is generally measured and marked prior to mounting the assembly to the newel posts.

**S..* * I

I

*.I... * *

Decks often include stairs, for example where a house is built on sloping ground which slopes downward from the front of the house to the rear, whereby the base of the rear door is above ground level. In such a case, a handrail assembly is generally constructed such that the handrail and the base rail run along the incline of the stairs, while the balusters remain vertically disposed therebetween.

Generally, there is more flexibility in determining the inclination of a staircase for decking than, for example, internal household staircases, where there are more space constraints.

Simplicity in design and ease of assembly are key requirernfl for handrail assemblies.

For contract builders, these factors Contribute to profitability For do-it-yourseff enthusiasts they may be the deciding factors which determine whether or not the project is completed successfully or even undertaken at all.

It is therefore a non-exclusive object of the present invention to provide a handrail assembly which assists and/or eases assembly and installation thereof.

Accordingly, one aspect of the invention provides a connector for securing two rails together, the connector comprising two parts pivotably connected together and stepwise adjustment means, each part comprising a receiving portion for receiving the end of a rail, the stepwise adjustment means being adapted to limit relative movement of the parts :..::: at predete,,jned relative angles for facilitating assembly of a handrail incorporating the * *** Connector. * *. * * S : 15 5.

The adjustment means may be provided by cooperating outer surfaces of the receiving portions. Preferably, one of the predetermined relative angles is approximately ninety *55*5* * degrees. More preferably, a further predetermined relative angle is approximately two hundred and seventy degrees.

Alternatively or additionally, the adjustment means further comprises one or more protrusions in one of the parts which cooperates with one or more further protrusions or depressions in the other part. Preferably, the parts comprise a plurality of protrusions and/or depressions to provide stepw,se adjustment of the relative angle of the parts, for example at 5, 10, 20, 30 or 450 (or multiples thereof) intervals.

Each part may further comprise an interface portion, for example wherein the interface portion of a first part is receivable in the interface portion of a second part.

The one or more protrusions may be located on an internal surface of the interface portion of the first part and the one or more further protrusions or depressions may be located on an external surface of the interface portion of the second part.

Alternatively, the one or more protrusions may be located on an external surface of the interface portion of the second part and the one or more depressions may be located on an internal surface of the interface portion of the first part.

One or each of the parts may comprise a support portion for securing the connector to an upright post. The or one of the support portions may comprise a top wall for resting on * S..

the top of the upright post. The support portions may comprise the interface portions. * .. *. .

lb.. 15

S

Optionally, one or each receiving portion comprises ribs on an internal surface thereof for : providing an interference fit with the rail. One or each receiving portion may further *S.lss * comprise at least one hole for receiving fastening means for securing the connector to the rail.

Preferably, the receiving portions are aligned substantially along the same plane.

A second aspect of the invention provides a connector for connecting a baluster to a rail, the Connector comprising a receiving portion for receiving the baluster and a securing portion for securing the connector to the rail, the securing portion comprising a body portion having a flat surface for cooperating with a flat surface of the rail and at least one wing portion having a curved surface for cooperating with a curved surface of the rail.

Preferably, the securing portion comprises two wing portions.

The receiving portion may comprise a wall, for example a circular wall, extending from the securing portion. The receiving portion may comprise ribs on an internal surface thereof for providing an interference fit with the first post.

The receiving portion may extend from the securing portion at an angle, for example up to forty-five degrees, say from 30 to 45, for example 35 to 42 degrees.

The securing portion may further comprise at least one hole for receiving fastening means to secure the connector to the baluster and/or rail. * . * *** *** * * *S*.

A third aspect of the invention provides a connector for connecting two posts together, * ** *:.. 15 the connector comprising a receiving portion for receiving a first post and a securing a.

portion for securing the connector to a second post, the securing portion comprising a a: plate having a curved surface for cooperating with a curved surface of the second post, the receiving portion extending from the securing portion at an oblique angle.

Preferably, the receiving portion comprises a wall, for example a circular wall, extending from the securing portion.

The receiving portion may comprise ribs on an internal surface thereof for providing an interference fit with the first post.

The securing portion may further comprise at least one hole for receiving fastening means for securing the connector to the first and/or second post.

The first post may be a rail. The second post may be an upright post, for example a newel post. Alternatively the posts may be any combination of rails, balusters or upright posts, for example newel posts.

A fourth aspect of the invention provides a support bracket for supporting a post, the bracket comprising a body, a flat surface for resting on a substrate and an opposed curved surface for cooperating with curved surface of the post.

The support bracket may further comprise a substrate securing portion which includes the flat surface and/or a cradle portion which includes the curved surface. The substrate securing portion may comprise a generally flat plate. The cradle portion may comprise a generally flat plate. The substrate securing portion may be connected to the cradle *...

portion by a strut member extending substantially perpendicularly therebetween. * *. * * S

The support bracket may further comprise at least one hole for receiving fastening means to secure the bracket to the post anWor to the substrate. The at least one hole * * may be located in the substrate securing portion. Alternatively or additionally, the at least one or a further hole may be located in the cradle portion.

The post may be a rail. The substrate may be a deck or a flat rail.

It will be appreciated that the support bracket may be used in a different configuration, for example the curved surface may rest on an curved surface of a rail while the flat surface may be used for supporting a rail having a flat surface.

A further aspect of the invention provides a kit of parts for assembly into a handrail structure, the kit comprising at least two rails and a connector according to the first aspect of the invention.

The kit preferably comprises an upright post.

A further aspect of the invention provides a kit of parts for assembly into a handrail structure, the kit comprising at least one rail, at least one baluster and at least one connector according to the second aspect of the invention.

A further aspect of the invention provides a kit of parts for assembly into a handrail structure, the kit comprising at least one rail, at least one upright post and at least one connector according to the third aspect of the invention. * **

The kit preferably comprises at least two upright posts and at least two connectors. I..

S

A further aspect of the invention provides a kit of parts for assembly into a handrail S.....

* structure, the kit comprising at least one rail and a support bracket according to the fourth aspect of the invention.

The kit preferably comprises at least two upright posts.

Any of the aforementioned kits may further comprise any combination of any of the aforementioned components. The kits may further comprise any combination of any other components described hereinbelow.

A further aspect of the invention provides a method of assembling a handrail structure comprising providing a connector according to the first aspect of the invention, inserting a rail into each of the receiving portions and securing the connector to an upright post.

A further aspect of the invention provides a method of assembling a handrail structure comprising providing a connector according to the second aspect of the invention, providing a rail with a cross section having a flat edge and an curved edge, positioning the securing portion of the connector on the rail such that the flat surface of the securing portion is adjacent the flat surface of the rail and such that the curved surface of the securing portion is adjacent the curved surface of the rail, securing the connector to the rail and inserting a baluster into the receiving portion of the connector.

I

: A further aspect of the invention provides a method of assembling a handrail structure * **.

comprising providing a first connector according to the third aspect of the invention, s:' 15 inserting one end of a rail into the receiving portion, positioning the securing portion of * the first connector adjacent an upright post and securing it thereto. * I

The method may further comprise the additional steps of inserting the other end of the rail into a second connector according to the third aspect of the invention such that the second connector is inverted relative to the first connector. Preferably, the method includes positioning the securing portion of the second connector adjacent a further upright post at the same time as the securing portion of the connector is positioned on the upright post.

A further aspect of the invention provides a method of assembling a handrail structure comprising positioning the flat surface of a support bracket according to the fourth aspect of the invention on a substrate, placing a rail onto the curved surface of the support bracket and securing the rail between two upright posts.

Preferably, the centre of the rail is placed onto the curved surface of the support bracket.

The rail may comprise a cross section having a flat edge and a curved edge.

The method may further comprise the additional step of positioning the securing portion of a connector according to the second aspect of the invention on the rail such that the flat surface of the securing portion is adjacent the flat surface of the rail and such that the curved surface of the securing portion is adjacent the curved surface of the rail and securing the connector to the rail. The method may also comprise inserting a baluster : .. into the receiving portion of the connector. * .

** *,* *..: 15 Any of the above methods may comprise any combination of further steps which will *** * become evident given the nature of the components described herein. *

*,**** * * One embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a handrail assembly according to the invention; Figure 2 is a perspective view of the handrail to partial newel post connector of the handrail assembly shown in Figure 1; Figure 3 is a perspective view of the one of the two-part intermediate handrail to newel post connectors of the handrail assembly shown in Figure 1; Figure 4 is a perspective view of the lower part of the two part connector of Figure 3; Figure 5 is a perspective view of the upper part of the two part connector of Figure 3; Figure 6 is a perspective view of the handrail to newel post connector of the handrail assembly shown in Figure 1; Figure 7 is a perspective view of the newel post cap of the handrail assembly shown in Figure 1; Figure 8 is a perspective view of one of the orthogonal rail to newel post connectors of the handrail assembly shown in Figure 1; * . * *** S...

Figure 9 is a perspective view of one of the inclined rail to newel post connectors of the handrail assembly shown in Figure 1; *

S

* * Figure 10 is a perspective view of the inclined round rail to flat surface connectors of the handrail assembly shown in Figure 1; Figure 11 is a perspective view of one of the orthogonal baluster to rail connectors of the handrail assembly shown In Figure 1; Figure 12 is a perspective view of one of the Inclined baluster to rail connector of the handrail assembly shown in Figure 1; and -. 10 Figure 13 is a perspective view of one of the rail support brackets of the handrail assembly shown in Figure 1.

Referring to Figure 1 there is shown a handrail assembly I fitted to the deck 10 of a house 11, the deck having a staircase 12. The handrail assembly 1 includes four newel posts 2, one partial newel post 3, four base rails 4, four upper rails 5, three handrails 6 and a plurality of balusters 7.

The handrail assembly I also includes a plurality of connector components for connecting and/or supporting the aforementioned members to one another. These can conveniently be separated into those used on level surfaces and those required for inclined arrangements.

The components used for level surfaces include one handrail to partial newel post : ... connector 61, two intermediate handrail to newel post connectors 62, one handrail to end s.

newel post connector 63, twelve rail to newel post connectors 51, a plurality of baluster to rail connectors 71 and six support brackets 52.

:0 The components used for inclined surfaces include three inclined rail to newel post connectors 53, one inclined rail to flat surface connector 54, a plurality of inclined baluster to rail connectors 72 and one newel post cap 21.

The newel posts 2 are elongate members and include a base portion 2a having a square cross-section and an upper portion 2b having a round cross-section. The partial newel post 3 is a half newel post split along its longitudinal axis. Thus, the partial newel post 3 has a base portion 3a having a rectangular cross-section and an upper portion 3b having a semi-circular cross-section.

The base rails 4 and upper rails 5 are elongate members and each have a substantial round cross-section with a fiat edge to describe a major segment of a circle. The handrails 6 are also elongate members but have a rectangular cross-section.

The balusters 7 are elongate members having a round cross-section.

Referring now to Figure 2, the handrail to partial newel post connector 61 includes a support portion 610 and a rail receiving portion 615.

The support portion 610 includes a side wall 611 and a top wall 612. The top wall 612 is semi-circular in shape with a fiat edge 612a and a curved edge 612b. The side wall 611 is semi-cylindrical in shape and extends downwardly from the curved edge 612a of the :... top wall 612 and has a height x. A portion of the side wall 611 is shared between the * *. S support portion 610 and the rail receiving portion 615. The portion of the side wall 611 :.:::S not shared with the rail receiving portion 615 includes two countersunk holes 613 through its thickness for securing. e.g. with screws, the connector 61 to the top of a partial newel :4 post 3.

S

* .5.55 * S The rail receiving portion 615 is essentially a socket for receiving a member having a rectangular cross-section. The receiving portion 615 is substantially wedge shaped in plan having side walls 615a, 615b which extend from the side wall 611 of the support portion 610 at approximately ninety degrees from one another and, at a position approximately mid way along their length, change direction to form portions which are substantially parallel. The receiving portion 615 also includes a top wall 615c and a bottom wall 615d. The top wall 615c and bottom wall 615d each include two parallel friction guides 616 which extend from the outer edge thereof toward the side wall 611 of the support portion 610. The bottom wall 615d also includes two holes 617 through its thickness for securing, e.g. with screws, the connector 61 to a handrail 6 inserted in the receiving portion 615.

In Figure 3 there is shown an intermediate handrail to newel post connector 62 which is made up of two part connectors 62a, 62b. The height of the two part connectors 62a, 62b in an assembled condition 62 is x. The part connectors 62a, 62b are shown separately in Figure 4 and 5 respectively.

Referring to Figure 4, the lower part connector 62a includes a support portion 620a and a rail receiving portion 625a.

The support portion 620a includes a loop 621a defining the circumference of a circle with ... a flange 622a extending inwardly from the bottom edge of the loop 621a. The loop 621a *I..

includes three countersunk holes 623a therethrougl, at spaced apart locations for ::::. securing, e.g. with screws, the lower part connector 62a to the upper portion 2b of a * newel post 2. On an inner surface of the loop 623 there is a plurality of recesses 624a, * regularly spaced at approximately 450 about the circumference thereof. * .

S

* S*II. * S

The rail receiving portion 625a is essentially a socket for receiving a member having a rectangular cross-section. The receiving portion 625a is shaped substantially the same as the rail receiving portion 615 of the rail 61 of Figure 2. The receiving portion 625a also includes parallel friction guides 626a on the internal surfaces thereof and two holes 627a through the thickness of the bottom wall thereof for securing, e.g. with screws, the lower part connector 62a to a handrail 6.

Referring to Figure 5, the upper part connector 62b includes a support portion 620b and a rail receiving portion 625b.

The support portion 620b includes a side wall 621b and a top wall 622b. The top wall 622b is substantially circular in shape. The side wall 621b is cylindrical in shape and extends downwardly from the penphery of the top wall 622b. A minor portion of the side waIl 621 b is shared between the support portion 620b and the rail receiving portion 625b.

The portion of the side wall 621 b not shared with the rail receiving portion 625b includes an upper portion having three spaced apart countersunk holes 623b through its thickness and a recessed lower portion 628b having a circumference recessed from that of the side wall 621 b. The lower portion 628b includes six spaced apart holes 629b through its thickness and axially aligned with the holes 623b in the upper portion of the side wall 621 b for securing, e.g. with screws, the upper part connector 62b to the top of a newel post 2. The lower portion 628b also includes on its outer surface a plurality of projections n... 824b, regularly spaced at approximately 45C about the circumference thereof. * * **.*

::::. The rail receiving portion 625b is essentially a socket for receiving a member having a rectangular cross-section. The receiving portion 625b is shaped substantially the same as the rail receiving portion 615 of the rail 61 of Figure 2. The receiving portion 625b * also includes parallel friction guides 626b on the internal surfaces thereof and two holes 627b through the thickness of the bottom wall thereof for securing, e.g. with screws, the upper part connector 62b to a handrail 6.

In an assembled condition, the projections 624b cooperate with the recesses 624a to provide stepwise adjustment of the relative angle between the part connectors 62a, 62b.

The outer surfaces of the receiving portions 625a, 625b also provide abutment surfaces, thereby limiting angular movement of the part connectors 62a, 62b at an angle of approximately 900 and 270 .

Consequently, the cooperating projections 624b and recesses 624a, together with the outer abutment surfaces of the receiving portions 625a. 625b, provide an assembly aid which ensures accurate angular positioning of interconnected handrails. This is particularly helpful for do-it-yourself enthusiasts, who require an arrangement which provides a good balance between flexibility and ease of assembly.

Referring now to Figure 6, there is shown a handrail to newel post connector 63, which includes a support portion 630 and a rail receiving portion 635.

The support portion 630 includes a side wall 631 and a top wall 632. The top wall 632 is circular in shape. The side wall 631 is cylindrical in shape and extends downwardly from the periphery of the top wall 632. A minor portion of the side wall 631 is shared between :... the support portion 630 and the rail receiving portion 635. The portion of the side wall

S

631 not shared with the rail receiving portion 635 includes three countersunk holes 633 through its thickness for securing, e.g. with screws, the connector 63 to the top of a newel post 2. *

The rail receiving portion 635 is essentially a socket for receiving a member having a rectangular cross-section. The receiving portion 635 is shaped substantially the same as the rail receiving portion 615 of the rail 61 of Figure 2. The receiving portion 635 also includes parallel friction guides 636 on the internal surfaces thereof and two holes 637 through the thickness of the bottom wall thereof for securing, e.g. with screws, the connector 63 to a handrail 6.

In Figure 7 there is shown a newel post cap 21, which comprises a side wall 211 and a top wall 212.

The top wall 212 is circular in shape. The side wail 211 is substantially cylindrical in shape and extends downwardly from the edge of the top wall 211. The side wall 211 includes a relatively short section and a relatively tall section with the height of the side wall 211 varying smoothly and continuously between these two extremes. The side wall 211 also includes a pair of opposed countersunk holes 213 therethrough for securing, e.g. with screws, the cap 21 to the top of a newel post 2.

In Figure 8 there is shown an orthogonal rail to newel post connector 51. The connector 51 comprises a support portion 510 and a rail receiving portion 515.

The support portion 510 is essentially a curved plate having an elliptical periphery in plan. The support portion 510 includes a central hole 512 and four countersunk holes n... 513 through its thickness. The central hole 512 is substantially circular in plan. The countersunk holes 513 are located marginally inward from the periphery of the support :* portion 510 for securing, e.g. with screws, the connector 51 to, say, a curved upper * : portion 2a of a newel post 2. Typically1 the shapes of the upper portion 2a of the newel post 2 and support portion 510 will be complementary such that they can lie in close * . : proximity when brought together.

The rail receMng portion 515 is substantially cylindrical in shape and extends from the edge of the central hole 512 of the support portion 510 in a direction substantially perpendicular to the principal axis of the support portion 510. The rail receiving portion 515 includes two opposed countersunk holes 517 for securing, e.g. with screws, the connector 51 to a rail 4, 5.

In Figure 9 there is shown an inclined rail to newel post connector 53. The connector 53 comprises a support portion 530 and a rail receiving portion 535.

The support portion 530 is essentially a curved plate having an elliptical penphery in plan. The support portion 530 includes a central hole 532 and four countersunk holes 533 through its thickness. The central hole 532 is elliptical in plan. The countersunk holes 533 are located marginally inward from the periphery of the plate for securing, e.g. with screws, the connector 53 to, say, a curved upper portion 2a of a newel post 2.

Typically, the shapes of the upper portion 2a of the newel post 2 and support portion 530 wifl be complementary such that they can lie in close proximity when brought together.

The rail receiving portion 535 is substantially cylindrical in shape and extends from the central hole 532 of the support portion 530 at an angle of approximately 45 degrees to the principal axis of the support portion 530. The rail receiving portion 535 includes two .. opposed countersunk holes 537 for securing, e.g. with screws, the connector 53 to a rail 5, 4. * .* * * ***.

In Figure 10 there is shown an inclined round rail to flat surface connector 54. The *,..2{) connector 54 comprises a support portion 540 and a rail receiving portion 545. * *

The support portion 540 is essentially a flat plate having an elliptical periphery in plan.

The support portion 540 includes a central hole 542 and four countersunk holes 543 through its thickness. The central hole 542 is elliptical in plan. The countersunk holes 543 are located marginally inward from the periphery of the support portion 540 for securing, e.g. with screws, the connector 54 to, say, the base portion 2b of a newel post 2. Typically, the shapes of the base portion 2b of the newel post 2 and support portion 540 will be complementary such that they can tie in close proximity when brought together.

The rail receiving portion 545 is substantially cylindrical in shape and extends from the edge of the central hole 542 of the support portion 540 at an angle of up to forty fiive degrees, and preferably at an angle of 30 to 42 degrees, say 38 degrees. The rail receiving portion 545 includes two opposed countersunk holes 547 for securing, e.g. with screws, the connector 54 to a rail 4, 5.

In Figure 11 there is shown a first baluster to rail connector 71. The connector 71 has a support portion 710 and a baluster receiving portion 715.

The support portion 710 is essentially a curved plate having an elliptical periphery in plan. The support portion 710 includes two curved wing portions 711 and a flat body portion 712. Each wing portion 711 includes a countersunk hole 713 through its thickness for securing, e.g. with screws, the connector 71 to a rail 4, 5. The holes 713 S..

are located marginally inward from the periphery of the wing portion 711. The flat body portion 712 includes a hole 717 through its thickness for securing, e.g. with screws, the connector 71 to a baluster 7. * .20 * *

The baluster receiving portion 715 is substantially cylindrical in shape and extends from the flat body portion 712 of the support portion 710. The baluster receiving portion 715 includes a plurality of axial ribs 716 on the internal surface thereof at spaced apart locations for providing an interference or friction fit with a baluster 7 inserted therein.

The lower surface of the support portion 710 is shaped so that the connector 71 can sit on or cradle the flat surface of one of the rails 4, 5 when the connector 71 is located at the bottom end or top end of a baluster 7 respectively, with the wing portions 711 embracing the curved surfaces of the rail 4, 5 to which it may be attached. This arrangement provides a simple and effective means of ensuring

proper location of the connector 71 on the rail 4, 5, thereby to provide a consistent and reliable orientation between all of the balusters 7 and the rails 4, 5.

In Figure 12 there is shown an inclined baluster to rail connector 72. The connector 72 has a support portion 720 and a baluster receiving portion 725.

The support portion 720 Is essentially a curved plate having an elliptical periphery in plan. The support portion 720 includes two curved wing portions 721 and a flat body portion 722. Each wing portion 721 includes a countersunk hole 723 through its thickness for securing, e.g. with screws, the connector 72 to a rail 4, 5. The holes 723 are located marginally inward from the periphery of the wing portions 721. The flat portion 722 is substantially circular in plan and includes a hole 727 through its thickness I...

for securing, e.g. with screws, the connector 72 to a baluster 7. * *0 ** p p...

The baluster receiving portion 725 is substantially cylindrical in shape and extends from the flat body portion 722 of the support portion 720 at an angle of up to forty flive * . :" degrees, and preferably at an angle of 30 to 42 degrees, say 38 degrees. The baluster receiving portion 725 includes a plurality of axial ribs 726 on the internal surface thereof at spaced apart locations for providing an interference fit with a baluster 7 located therein.

The lower surface of the support portion 720 is shaped so that the connector 72 can sit on or cradle the flat surface of one of the rails 4, 5 when the connector 72 is located at the bottom end or top end of a baluster 7 respectively, with the wing portions 721 embracing the curved surfaces of the rail 4, 5 to which it may be attached.

As with the baluster to rail connector 71, this arrangement provides a simple and effective means of ensuring proper location of the connector 72 on the rail 4, 5, thereby to provide a consistent and reliable orientation between all of the balusters 7 and the rails 4,5.

In Figure 13 there is shown a rail support bracket 52. The rail support bracket 52 comprises a substrate securing portion 520, a strut member 522 and a cradle portion 525.

The substrate securing portion 520 is essentially a flat plate having an elliptical periphery in plan. The substrate securing portion 520 includes a pair of countersunk holes 523 for securing, e.g. with screws, the rail support bracket 52 to a substrate 10, 6. The strut :... member 522 is an elongate member and extends perpendicularly from the substrate I...

securing portion 520 such that, in use, the strut member 522 extends away from the surface 10 to which the rail support bracket 52 is attached.

S

At the opposite end of the strut member 522 from the substrate securing portion 520 is

S I

:" located the cradle portion 525. The cradle portion 525 is essentially a curved plate having an elliptical periphery in plan and has a convex lower surface 525a and a concave upper surface 525b. The strut member 522 is joined to the lower surface 525a of the cradle portion 525. The concave upper surface 525b of the cradle portion 525 is shaped to support a rail 4, 5. The cradle portion 525 also includes a pair of holes 527 for securing, e.g. with screws, the rail support bracket 52 to a rail 4, 5.

In a preferred embodiment of the invention, a kit of parts is provided which includes all of the above components. The posts 2, 3, 4, 5, 6, and 7 may be provided in standard lengths. Some or all, for example the rails 4, 5, 6, may be easily cut as required by the circumstances. The ends (not shown) of the balusters 7 for use in the inclined portion of the handrail structure are preferably cut at the requisite angle, or at least approximate thereto.

The base rails 4 and upper rails 5 may be provided with pre-drilled holes (not shown) for receiving fastening means, for example screws (not shown), for securing the baluster to rail connectors 71 thereto. This arrangement would be beneficial if the handrails are of a pre-determined length.

However, do-it-yourself enthusiasts will likely require, or desire, flexibility in the baluster spacing and therefore the base rails 4 and upper rails 5 may also be provided without pre-dnlled holes. S. * * * *.* I...

A method of assembling a handrail assembly according to the invention will now be : described with reference to the assembly shown in Figure 1, although it will be appreciated that different designs and/or compositions of components may be required for different applications. * * *

S..... * S

A first newel post 2 is positioned and secured to the deck 10 beside the bottom tread of the flight of stairs 12. A second newel post 2 is positioned and secured to the deck 10 beside the top of the flight of stairs 12. A third newel post 2 is positioned and secured to a corner of the deck 10; a fourth newel post 2 is positioned at a distance along an edge of the deck 10 towards a house 11 and secured to the deck 10; and a partial newel post 3 is positioned along the same edge of the deck 10 and adjacent the house 11 and secured to the deck 10 and/or the house 11.

A baluster to rail connector 71 is then preferably pre-secured to one end of each of a plurality of balusters 7 by inserting the end of each baiuster 7 into the baluster receiving portion 715 of a connector 71. A screw (not shown) is then inserted through the hole 717 in the flat body portion 712 of each connector 71 from the underside thereof and fastened to the baluster 7. The ribs 716 retain the balusters 7 in position, thereby aiding assembly.

The connected balusters and connectors 7, 71 can then be pre-secured to three base rails 4. The balusters and connectors 7, 71 are first placed onto the rails 4 such that the flat portion 712 of the support portion 710 of each connector 7 rests on the flat surface of the rail 4. Screws (not shown) are then inserted through the holes 713 in the wing portions 711 of the connectors 71 and fastened onto the rails 4. A spacer (not shown) may be used to ensure that the spacing between successive balusters 7 is the same. * . ***.

Each end of each base rail 4 is then inserted into a rail to newel post connector 51 in the orientation shown in Figure ito form a base rail assembly 4,51,71,7. :2o * *

A plurality of baluster to rail connectors 71 can then be pre-secured to three upper rails 5.

The connectors 71 are first placed onto the rails 5 such that the flat portion 712 of the support portion 710 rests on the flat surface of the rail 5. Screws (not shown) are then inserted through the holes 713 in the wing portions 711 of the connectors 71 and fastened into the rails 5. A spacer (not shown) may be used to ensure that the spacing between successive connectors 71 is the same.

Each end of each upper rail 5 is then inserted into a rail to newel post connector 51 in the orientation shown in Figure 1 to form an upper rail assembly 5, 51, 71.

One support bracket 52 is preferably placed on the deck 10 between each of the second, third, fourth and partial newel posts 2, 3 such that the flat surface of the substrate securing portion 520 is in contact with the deck and the curved surface 525b of the cradle portion 525 is upwardly facing.

The first of the base rail assemblies 4, 51, 71, 7 is then lowered between second and third newel posts 2 until a lower curved surface of the base rail 4 rests in the cradle portion 525 of the support bracket 52. A spirit level (not shown) may then be used to ensure that the base rail 4 is properly levelled. However, it will be appreciated that the user may simply use the support bracket 52 iii conjunction with measuring the fixing height at one of the two posts 2 to ensure the base rail assembly 4, 51, 71, 7 is level.

The base rail assembly 4, 51, 71, 7 is then secured to the second and third newel posts 2 a...

by fastening screws (not shown) therein through the holes 513, 517 of the rail to newel . postconnectors5l. a S..

S

The cradle portion 525 of the support bracket 52 is then secured to the base rail 4 by fastening screws (not shown) therein through the holes 527 of the cradle portion 525.

The substrate securing portion 520 is then secured to the deck 10 by fastening screws (not shown) therein through the holes 523 of the substrate securing portion 520.

The second of the base rail assemblies 4, 51, 71, 7 is then lowered between third and fourth newel posts 2 until a lower curved surface of the base rail 4 rests in the cradle portion 525 of the support bracket 52 and the above procedure is repeated for the second base rail assembly 4, 51, 71. 7.

The third of the base rail assemblies 4, 51, 71, 7 is then lowered between the fourth newel post 2 and the partial newel post 3 until a lower curved surface of the base rail 4 rests in the cradle portion 525 of the support bracket 52 and the above procedure is repeated for the third base rail assembly 4, 51, 71, 7.

The first of the upper rail assemblies 5, 51, 71 is then lowered between second and third newel posts 2 with the baluster to rail connectors 71 facing downwardly. The free ends of the balusters 7 are inserted into the corresponding baluster receiving portion 715 of the baluster to rail connectors 71 of the first upper rail assembly 5, 51, 71. The upper rail assembly 5, 51, 71 is then secured to the second and third newel posts 2 by fastening screws (not shown) therein through the holes 513, 517 of the rail to newel post connectors 51. S. * S.. *5Ss

The second of the upper rail assemblies 5, 51, 71 is then lowered between third and fourth newel posts 2 with the baluster to rail connectors 71 facing down and the above procedure is repeated for the second upper rail assembly 5, 51, 71. * S

The third of the upper rail assemblies 5, 51, 71 Is then lowered between fourth newel post 2 and partial newel post 3 with the baluster to rail connectors 71 facing down and the above procedure is repeated for the third upper rail assembly 5, 51, 71.

A first end of a first handrail 6 is then inserted into a handrail to end newel post connector 63 and a second end thereof is inserted into a lower part connector 62a of an intermediate handrail to newel post connector 62.

The first handrail 6 is then lowered between the second and third newel posts 2 such that the end newel post connector 63 receives the second newel post 2 and the loop 621a of the lower part connector 62a receives the third newel post 2. A support bracket 52 iS preferably placed on an upper surface of the upper rail 5, such that the curved surface 525b of the cradle portion 525 is in contact with therewith, and held in place while the handrail 6 continues to be lowered. As the handrail 6 is lowered, the flat surface of the substrate securing portion 520 contacts the handrail 6.

The use of the support bracket 52 facilitates levelling and installation of the handrail 6. In particular, the support bracket 52 precludes the need to fix the lower part connector 62a on the second end of the first handrail 6 to the third newel post during installation.

The handrail 6 is then secured to the second newel post 2 by fastening screws (not .i5 shown) through the holes 633, 637 of the end newel post connector 63. The lower part *.*.. connector 62a is then secured to the handrail 6 by fastening screws (not shown) therein : ** through the holes 627a. The handrail 6 is then secured to the upper rail 5 by fastening S...

*. screws (not shown) through the holes 527, 523 of the support bracket 52.

I.....

? A first end of a second handrail 6 is then inserted into an upper part connector 62b of the intermediate handrail to newel post connector 62 and a second end thereof is inserted into a further lower part connector 62a of a further intermediate handrail to newel post connector 62.

The second handrail 6 is then lowered between the third and fourth newel posts 2. In doing so, the support portion 620b of the upper part connector 62b of the intermediate handrail to newel post connector 62 receives the third newel post 2 and the loop 621a of the lower part connector 62a receives the recessed lower portion 628b of the upper part connector 62b. The upper part connector 62b is then adjusted to the requisite angle, in this case ninety degree, such that the projections 624b of the upper part connector 62b slot into the recess portions 624a of the lower part connector 62a. This arrangement provides positive alignment and a relatively rigid connection.

As the second handrail 6 is lowered, the loop 621a of the further lower part connector 62a also receives the fourth newel post. A support bracket 52 is preferably placed on an upper surface of the upper rail 5, such that the curved surface 525b of the cradle portion 525 is in contact with therewith, and held in place while the second handrail 6 continues to be lowered. As the second handrail 6 is lowered, the flat surface of the substrate securing portion 520 contacts the handrail 6.

The second handrail 6 is then secured to the upper part connector 62b by fastening screws (not shown) therein through the holes 627b. The first and second handrails 6 are I...

secured to the third newel post 2 by fastening screws (not shown) through the holes 623a, 629b, 623b of the first intermediate handrail to newel post connector 62. The three ** holes 623a in the lower part connector 62a are automatically aligned with three of the holes 629b in the lower portion 628b of the upper part connector 62b by virtue of the * .20 alignment of the projections 624b and recess portions 624a.

The handrail 6 is then secured to further lower part connector 62a by fastening screws (not shown) therein through the holes 627a. The handrail 6 is then secured to the upper rail 5 by fastening screws (not shown) through the holes 527, 523 of the support bracket 52.

A first end of a third handrail 6 is then inserted into a further upper part connector 62b of a further intermediate handrail to newel post connector 62 and a second end thereof is inserted into a handrail to partial newel post connector 61.

The third handrail 6 is then lowered between the fourth and partial newel posts 2, 3. In doing so, the support portion 620b of the further upper part connector 62b receives the fourth newel post 2 and the loop 621a of the further lower part connector 62a receives the recessed lower portion 628b of the further upper part connector 62b. The further upper part connector 62b is then adjusted to the requisite angle, in this case one hundred and eighty degrees, such that the projections 624b slot into the recess portions 624a.

As the third handrail 6 is lowered, the support portion 610 of the handrail to partial newel post connector 61 receives the partial newel post 3. A support bracket 52 is preferably placed on an upper surface of the upper rail 5, such that the curved surface 525b of the cradle portion 525 is in contact with therewith, and held in place while the third handrail 6 continues to be lowered. As the third handrail 6 is lowered, the flat surface of the : *. substrate securing portion 520 contacts the handraIl 6.

S

S S.'

S

The third handrail 6 is then secured to the further upper part connector 62b by fastening * . screws (not shown) therein through the holes 627b. The second and third handrails 6 are secured to the fourth newel post 2 by fastening screws (not shown) through the holes 623a, 629b, 623b of the further intermediate handrail to newel post connector 62. The three holes 623a in the further lower part connector 62a are automatically aligned with three of the holes 629b in the lower portion 628b of the further upper part connector 62b by virtue of the alignment of the projections 624b and recess portions 624a.

The handrail to partial newel post connector 61 is then secured to the partial newel post 3 by fastening screws (not shown) therein through the holes 613. The handrail 6 is then secured to the upper rail 5 by fastening screws (not shown) through the holes 527, 523 of the support bracket 52.

An inclined baluster to rail connector 72 is preferably pre-secured to one end of each of a plurality of balusters 7 by inserting the end of each baluster 7 into the baluster receiving portion 725 of a connector 72. A screw (not shown) is then inserted through the hole 727 in the flat body portion 722 of each connector 72 from the underside thereof and fastened to the baluster 7. The ribs 726 retain the balusters 7 in position, thereby aiding assembly.

The connected balusters and connectors 7, 72 can then be pre-secured to a base rail 4.

The connectors 72 are first placed onto the rails 4 such that the flat portion 722 of the .J support portion 720 rests on the flat surface of the rail 4. Screws (not shown) are then ... inserted through the holes 723 in the wing portions 721 of the connectors 72 and fastened into the rails 4. A spacer (not shown) may be used to ensure that the spacing * between successive connectors 72 is the same.

*1sp*. * .

* .. . .20 One end of the base rail 4 is inserted into an inclined rail to flat surface connector 54 and * S the other end is inserted into a rail to newel post connector 53 in the orientation shown in Figure 1 to form an inclined base rail assembly 4, 53, 54, 72, 7.

A plurality of inclined baluster to rail connectors 72 can then be pre-secured to an upper rail 5. The connectors 72 are first placed onto the rails 5 such that the fiat portion 722 of the support portion 720 rests on the flat surface of the rail 5. Screws (not shown) are then inserted through the holes 723 in the wing portions 721 of the connectors 72 and fastened into the rails 5. A spacer (not shown) may be used to ensure that the spacing between successive connectors 72 is the same.

Each end of the upper rail assembly 5, 72 is then inserted into an inclined rail to newel post connector 53 in the orientation shown in Figure 1 to form an inclined upper rail assembly 5, 53, 72.

The inclined base rail assembly 4, 53, 54, 72, 7 is then lowered into the requisite position between newel posts 2 and secured at a first end to the upper portion 2b of the first newel post 2 by fastening screws (riot shown) therein through the holes 533 of the inclined rail to newel post connector 53 and at the other end to the base portion 2a of the second newel post 2 by fastening screws (not shown) therein through the holes 543 of the inclined rail to fiat surface connector 54.

The inclined upper rail assembly 5, 53, 72 is then lowered between first and second *.S.

* .... newel posts 2 with the inclined baluster to rail connectors 72 facing down. The free ends : *. of the balusters 7 of the inclined base rail assembly 4, 53, 54, 72, 7 are then inserted into the corresponding baluster receiving portion 725 of the inclined baluster to rail *..,: connectors 72 of the inclined upper rail assembly 5, 53, 72. The inclined upper rail *:.. assembly 5, 53, 72 is then secured to the first and second newel posts 2 by fastening screws (not shown) therein through the holes 533 of the inclined rail to newel post connectors 53.

A cap member 21 is then positioned on top of the first newel post 2 to improve the aesthetics of the newel post 2 and the handrail assembly as a whole. The cap member 21 is then secured to the first newel post 2 by fastening screws (not shown) therein through the holes 213.

It will be appreciated by those skilled in the art that the nature of the inclined connectors 53, 54, 72 allows a single connector design 53, 54, 72 to be used at both ends of a rail 4, or a baluster 7 by simply inverting the orientation thereof.

It will also be appreciated that the configuration of holes 623a in the lower part connector 62a in co-operation with the configuration of the holes 629b in the lower portion 628b of the upper part connector 62b results in three pairs of holes 623a, 629b being in alignment when the two-part connector 62 is adjusted to any of the pre-determined angles. Any number of variations in configuration and/or numbers of holes are envisaged in order to provide this feature, all of which are within the scope of the invention.

It should be apparent to the person skilled in the art that numerous modifications could be made to the examples described above without departing from the scope of the * *** present invention. * .* ** * I..

For example, the sequence of assembling the baluster to rail connectors 71 which are secured to the upper rails 5 may be altered. The connectors 71 may first be placed on * : * * the upper end of the balusters 7 with the base rail assembly 4, 51, 71, 7 in place or placed on a jig (not shown). The upper rail 5 may be placed on the connectors 71, thereby to ensure proper alignment. The upper rail 5 may then be removed, the connectors 71 being secured to the balusters by fastening screws (not shown) therein through the holes 717. The upper rail 5 may then be fastened to the assembly 4, 51, 71, 7 by fastening screws (not shown) therein through the holes 713 of the wing portions 711, thereby to provide a fully assembled balustrade which may be fixed between posts with relative ease.

Alternatively, the above method may be carried out with the base rail assembly 4, 51, 71, 7 secured between posts rather than being placed on a jig (not shown).

In such cases, it may be beneficial to configure the baluster to rail connectors 71 without ribs 716 to allow for relative movement between the balusters 7 and connectors 71. A similar method and arrangement may be applied to the inclined baluster to rail connectors 72.

Moreover, almost any combination of any number of the components described herein could be employed in order to provide a multitude of handrail assemblies.

The method of assembly disclosed herein relates directly to the assembly shown in Figure 1. However, this particular arrangement does not benefit from the forty-five degree stepwise adjustment feature of the two-part connector 62, which is an important *S..

i* feature thereof. * S. * S S S...

It will be appreciated by those skilled in the art that this feature allows do-it-yourself enthusiasts to easily construct handrail assemblies having, for example, 450 corners in combination with 90 corners, and so on, using a single design of intermediate connector 62.

Various features of the components of the invention may also be varied without departing from the scope of the invention.

For example, whilst the recesses 624a and the projections 624b in the embodiment disclosed herein are regularly spaced at 45 , it will be appreciated that this angle may vary without departing from the scope of the invention.

Moreover, whilst the inclination of the inclined connectors 52, 54 and 72 is approximately 45 , any number of inclinations are possible depending on the requirements of a particular application.

The recesses 624a and projections 624b may be in different locations of the surfaces to provide different stepwise angles. Additionally or alternatively, the recesses 624a and projections 624b may be on different connector parts 62a, 62b and/or be shaped differently according to the requirements. For example deeper recesses 624a may be used in conjunction with larger projections to provide more rigid interference therebetween and therefore a more rigid connection. The recesses 624a may be wider :4$ than the width of the projections 624b to provide "play" therebetween. The projections * S..

may comprise straight sides which cooperate with straight recess sides and so on. * .. S. I

The receiving portions 615, 625a, 625b, 635, 515, 535, 545, 715 and 725 may be configured to receive rails or balusters of any cross sectional shape, such as square, * : rectangular, elliptical or otherwise, without departing from the scope of the invention.

Similarly, the portions 610, 620a, 620b, 630, 21, 510, 530 and 540 which interface with the newel posts 2 may be configured to interface with newel posts of any cross-sectional shape, such as square, rectangular, elliptical or otherwise.

The support brackets may be of any suitable shape or size for aesthetic and/or functional purposes. For example, the support bracket may simply comprise a block or cylinder, which is solid or hollow and configured to provide one curved surface and one flat surface.

It wiH be appreciated that the assembly and components thereof are particularly suited to a round' aesthetic, i.e. the balusters, newel posts, rails. Of course, this can be altered to suit particular design needs. However, the exemplary embodiments do provide a way in which the relatively unskilled worker can construct a balustrade having a round' aesthetic which has heretofore been difficult. S. * S * SS. S... * S * S. * S * *5S5 *55 S... * S *.... S *

Claims (27)

CLAI MS

1. A connector for securing two rails together, the connector comprising two parts pivotably connected together and stepwise adjustment means, each part comprising a receiving portion for receiving an end of a rail, the stepwise adjustment means being adapted to limit relative movement of the parts at predetermined relative angles for facilitating assembly of a handrail incorporating the connector.

2. A connector according to Claim 1, wherein the adjustment means is provided by cooperating outer surfaces of the receiving portions. Co

C

3. A connector according to Claim 1 or Claim 2, wherein one or each of the

C

parts comprises a support portion for securing the connector to an upright O post.

4. A connector for connecting a baluster to a rail, the connector comprising a receiving portion for receiving the baluster and a securing portion for securing the connector to the rail, the securing portion having a flat surface for cooperating with a flat surface of the rail and at least one wing portion having a curved surface for cooperating with a curved surface of the rail.

5. A connector according to Claim 4, wherein the securing portion comprises two wing portions.

6. A connector for connecting two posts together, the connector comprising a receiving portion for receiving a first post and a securing portion for securing the connector to a second post, the securing portion comprising a plate having a curved surface for cooperating with a curved surface of the second post, the receiving portion extending from the securing portion at an oblique angle.

7. A connector according to Claim 6, wherein the securing portion comprises ribs on an internal surface thereof for providing an interference fit with the first post. Co

C

(0

8. A support bracket for supporting a post, the bracket comprising a body, a C flat surface for resting on a substrate and an opposed curved surface for cooperating with a curved surface of the post.

9. A support bracket according to Claim 8, wherein the bracket further comprises a substrate securing portion which includes the flat surface and/or a cradle portion which includes the curved surface.

1 0. A kit of parts for assembly into a handrail structure, the kit comprising at least two rails and a connector according to Claim 1, Claim 2 or Claim 3.

11. A kit of parts for assembly into a handrail structure, the kit comprising at least one rail, at least one baluster and at least one connector according to Claim 4 or Claim 5.

12. A kit of parts for assembly into a handrail structure, the kit comprising at least one rail, at least one upright post and at least one connector according to Claim 6 or Claim 7.

13. A kit of parts for assembly into a handrail structure, the kit comprising at least one rail and a support bracket according to Claim 9.

14. A kit of parts for assembly into a handrail structure, the kit comprising any combination of one or more of the components according to any of Claims lto9. Co

C

(0

15. A handrail structure including at least one component according to any of C Claims 1 to 9. c'J

C

16. A method of assembling a handrail structure, the method comprising: * providing a connector according to Claim 1, Claim 2 or Claim 3; * inserting a rail into each of the receiving portions; and * securing the connector to an upright post.

17. A method of assembling a handrail structure, the method comprising: * providing a connector according to Claim 4 or Claim 5; * providing a rail with a cross section having a flat edge and a curved edge; * positioning the securing portion of the connector on the rail such that the flat surface of the securing portion is adjacent the flat surface of the rail and such that the curved surface of the securing portion is adjacent the curved surface of the rail; a securing the connector to the rail; and * inserting a baluster into the receiving portion of the connector.

18. A method of assembling a handrail structure, the method comprising: * providing a first connector according to Claim 6 or Claim 7; * inserting one end of a rail into the receiving portion; and * positioning the securing portion of the first connector adjacent an upright post and securing it thereto.

19. A method according to Claim 18, the method further comprising the additional steps of: C * inserting the other end of the rail into a second connector according to Claim 6 or Claim 7 such that the second connector is inverted relative to the first connector.

20. A method of assembling a handrail structure, the method comprising: * positioning the flat surface of a support bracket according to Claim 8 or Claim 9 on a substrate; * placing a rail onto the curved surface of the support bracket; and * securing the rail between two upright posts.

21. A handrail assembly as described and/or illustrated herein.

22. A connector for securing two rails together as described and/or illustrated herein.

23. A connector for connecting a baluster to a rail as described and/or illustrated herein.

24. A connector for connecting two posts together as described and/or illustrated herein.

25. A support bracket for supporting a post as described and/or illustrated herein. Co

C

26. A kit of parts for assembly into a handrail structure as described and/or C illustrated herein. c'J

C

27. A method of assembling a handrail structure as described herein.