Abstract:
Arrangements including pressing arrangements of dies are provided as well as processes for pressing a contour into tubular material. Handrails and docks having a handrail thereon are provided. Processes for disembarking/embarking between a floating vessel and a dock are provided.

Description:
CLAIM FOR PRIORITY 
       [0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 60/926,378 which was filed on Apr. 26, 2007, the entirety of which is incorporated by reference herein. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates generally to railing fabrication methods and more particularly to handrails, and metal fabrication methods. 
       BACKGROUND 
       [0003]    Handrails are utilized on a daily basis for negotiation of stairs and ramps. Typically, handrails are outdoors and they must suffer with the elements of outdoors, standing the test of time through winter, summer, and fall. As such, it is desired that handrails are durable, and at the same time provide a surface that can be easily grasped and released. The present disclosure provides handrails heretofore unknown in the art, as well as methods for producing rails and tubular bodies that can be used for other purposes beyond traditional handrail use. 
       SUMMARY 
       [0004]    Arrangements of dies are provided that can include a first die and a second die, the dies having adjoining surfaces complimentary to one another, wherein each of the dies further define opposing openings configured to receive material for pressing; and wherein a first surface of the opposing opening of the first die defines a different shape than a second surface of the opposing opening of the second die. 
         [0005]    Pressing arrangements of a plurality of dies are provided with the arrangement including: a plurality of first dies aligned across from a plurality of second dies, the dies having adjoining surfaces complimentary to one another, wherein each of the dies further define opposing openings configured to receive material for pressing; and wherein the plurality comprises a first group of first and second dies having first surfaces of the opposing openings of the first dies defining a different shape than second surfaces of the opposing openings of the second dies. 
         [0006]    Processes for pressing a contour into tubular material are provided that can include aligning the tubular material between two sets of dies, one of the sets comprising substantially planar pressing surface in relation to a relatively non-planar pressing surface of the other set; and pressing one set toward the other set to form a contour on the exterior of the tubular material. 
         [0007]    Handrails are provided that can include both vertical and horizontal portions, the vertical portion supporting the horizontal portion, wherein the at least one of the portions comprises peripheral exterior surfaces, one of the surfaces being relatively planar in comparison to another surface in one cross section. 
         [0008]    Docks having a handrail thereon are provided with, the handrail comprising both vertical and horizontal portions, the vertical portion supporting the horizontal portion, wherein the at least one of the portions comprises peripheral exterior surfaces, one of the surfaces being relatively planar in comparison another surface in one cross section. 
         [0009]    Processes for disembarking/embarking between a floating vessel and a dock are provided, with the process including stabilizing oneself with a handrail extending from the dock and transitioning between the dock and the floating vessel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    Preferred embodiments of the disclosure are described below with reference to the following accompanying drawings. 
           [0011]      FIG. 1  are exemplary dies of the present disclosure. 
           [0012]      FIG. 2  is an exemplary arrangement of two dies according to an embodiment. 
           [0013]      FIG. 3  is a cross-section of a lower die of  FIG. 3  according to an embodiment. 
           [0014]      FIG. 4  is an exemplary arrangement of the dies of  FIG. 1  according to an embodiment. 
           [0015]      FIG. 5  is an arrangement of dies having a blank therebetween according to an embodiment. 
           [0016]      FIG. 6  is an arrangement of dies between a press having a blank therebetween according to an embodiment. 
           [0017]      FIG. 7  is the arrangement of  FIG. 6  at a finished position according to an embodiment. 
           [0018]      FIG. 8  is a piece part according to an embodiment. 
           [0019]      FIG. 9  is a pressing arrangement having a blank therebetween according to an embodiment. 
           [0020]      FIG. 10  is the fabrication of a piece part according to an embodiment. 
           [0021]      FIG. 11  is a handrail supported by a dock assembly according to an embodiment. 
           [0022]      FIG. 12A  is a piece part for a land-based application according to an embodiment. 
           [0023]      FIG. 12B  is another orientation of the piece part of  FIG. 12A  according to an embodiment. 
           [0024]      FIG. 12C  is another piece part for a land-based application according to an embodiment. 
           [0025]      FIG. 12D  is another piece part for a land-based application according to an embodiment. 
       
    
    
     DESCRIPTION 
       [0026]    Example embodiments of the rail assemblies and metal fabrication methods including methods of manufacturing rail assemblies are described with reference to  FIGS. 1-12 . Turning first to  FIG. 1 , a plurality of dies are shown, particularly a series of ten (10) dies that can include first and second dies such as upper dies A and lower dies B. This can be referenced as a pressing arrangement of a plurality of dies, for example. The first dies can be aligned across from the second dies. 
         [0027]    According to an embodiment, upper dies A can be formed from a blank piece of tool steel, the blank having similar size as the blank used to form lower die B. These dies can be approximately 4″ wide and approximately 4″ tall and on average about 1″ in depth, for example. Alternative sizes of the dies, depending, for example, on the material to be processed or the desired processing, are contemplated. According to an example embodiment, die piece A can have an opening formed in the middle approximately 1.5″ in diameter and be split longitudinally across the opening. Lower dies B can have an opening approximately 1.375″ in diameter formed in the center, and then split through the opening to form two pieces as in upper die A, for example. Upper die A be configured to press material into lower die B. 
         [0028]    Referring to  FIG. 2 , dies A and B can be associated with one another, wherein die A is above die B, or die B is above die A. It is contemplated that where dies A and B converge or interface, their structure at the interface may compliment one another. As an example, die A may have adjoining surface  24  and die B can have adjoining surface  22 . According to an example embodiment, surfaces  22  and  24  may well be relatively planar in relation to one another. 
         [0029]    Die A may define an opening  28  and die B can define opening  26  with both openings  28  and  26  configured to receive material for pressing. As such the openings can oppose one another when operatively aligned. As an example, opening  28  can have a surface  29  and opening  26  can have a surface  30 . Surface  29  can define a different shape than surface  30 . Surface  29  can be relatively planar when compared to surface  30 . As an example, surface  29  can be a sheer, flat opening that extends from the lateral face of die A to the other lateral face. Surface  30 , for example, such as surface  30  of die B can have a contour to the interior wall of its opening, such as a convex contour. 
         [0030]    Referring to  FIG. 3 , this interior wall is shown as a cross-section of  FIG. 2 . This contour of the interior face of the opening of die B is shown in  FIG. 3  as contour  30 . Contour  30  can be an elevated portion within the center of the opening of die B extending from lateral face  32  to lateral face  34  of die B. 
         [0031]    Referring to  FIG. 4 , in accordance with an example aspect, a plurality of dies can be arranged in groups. Pressing arrangement  10  can include a group  44  and end group  42 . Group  42  can be on the periphery of group  44  and group  44  can include dies A and B, with these dies having opening surfaces of different shapes. Group  42  can include dies having like opening surfaces such as dies A. According to an embodiment, upper dies A can be opposed to one another at end portions  42 , for example. In accordance with example implementations, having end portions  42  configured in this manner may facilitate processing by alleviating at least some of the shifting of the blank as it is being formed. Dies A and B can be placed opposing one another throughout the distance between end portions  42 , for example. While shown in  FIG. 4  that a series of three (3) opposing portions of A and B are shown, the present disclosure contemplates various configurations of A opposing B, such as with blank A&#39;s in between sections with A opposing B, and/or multiple A&#39;s and B&#39;s in a series. For example, depending upon the desired amount of contoured piece parts to be shown later, many alternative sequences of A and B may be utilized. 
         [0032]    Referring to  FIG. 5 , a piece part  50  such as tubular material can be aligned between two sets of dies, such as between upper dies A and lower dies A and B. This piece part can comprises tubular steel, tubular aluminum, stainless steel, and/or aluminum electric weld, for example. The tubular steel can be round-sided tubular steel; however, tubular steel having flat sides is also contemplated. According to an example implementation, flat-sided tubular steel may be processed utilizing dies having complementary flat-sided interiors. As an example, square tubular steel may be processed using dies having square interior openings. The tubular steel may be treated or it can be tubular aluminum, such as anodized aluminum, or any form of tubular steel may be utilized. 
         [0033]    Referring to  FIG. 6 , blank or piece part  50  is shown in between dies A and B with pressing apparatus  60  to be applied to upper dies A, forcing the fabrication of portions of part  50  in accordance with dies B. Dies can be pressed together, one set toward the other, to form a contour on the exterior of the part. According to an example fabrication method, pressing device  60  may be configured to apply upwards of as much as 1500 lbs per square inch pressure to a blank having a 1.5″ diameter. The tubing itself, or part  50 , may have walls as thick or as thin as 1/32 inch or as large as ¼ inch. In accordance with exemplary embodiments, pressing assembly  60  is shown in the first position. Referring to  FIG. 7 , pressing assembly  60  is shown in the second or pressed position, wherein contours of die B are shown formed within piece  50 . Referring to  FIG. 8 , a processed piece  50  is shown, having contours  80  on at least one side of piece  50 . Contours  80  can include sets of peaks and valleys in one cross section. As an example, piece  50  can be tubular material and upon processing the tubular material can have a contour therein. The material can have peripheral exterior surfaces with one of the surfaces being relatively planar in comparison to the other surface in one cross section. 
         [0034]    Referring now to  FIG. 9 , according to an embodiment of the disclosure, part  90  can have portions in non-linear relation to one another such as the form of a U-shaped or U-bent piece of tubular material with one portion being substantially normal in relation to another portion. The U-bent tubular material may have two longer extending portions and a short connecting portion therebetween, for example. In accordance with at least one embodiment, one of the extending portions can be placed between dies as shown and pressed to form contours on the interior facing side. The piece may then be rotated or positioned further down the extending portion to provide even further contours along that extending portion. Referring to  FIG. 10 , the piece may then be rotated to a position wherein the shorter connecting portion is placed between the dies and contours are placed along the interior walls of that connecting portion of the U-shaped blank material. According to an exemplary embodiment, a handrail may be formed in this fashion. 
         [0035]    Referring now to  FIG. 11 , a handrail  111  can include both vertical and horizontal portions such as two extending portions  110  and a connecting portion  112 . As an example, extending portions  110  can be considered vertical portions and connecting portion  112  considered a horizontal portion. At least one of the portions can include peripheral exterior surfaces, one of the surfaces being relatively planar in comparison to another surface in one cross section. 
         [0036]    According to another implementation, both horizontal and one vertical portion can include interior contours. In a depicted embodiment, the horizontal portion can extend relatively normally from the vertical portion. According to example implementations, rail  111  can have vertical heights of 8, 16, or 32 inches relating to the vertical portions, and widths of 12 inches relating to the horizontal portions. According to exemplary embodiments, connecting portion  112  can provide at least a 7″ distance between extending portions  110 . To the extending portions  110  a flange  114  can be provided to connect the rail assembly to a substrate. 
         [0037]    In the exemplary embodiment shown in  FIG. 11 , the substrate can be dock  116 , such as a floating dock. Flanges  114  can be rounded or square, for example, the top edges of flanges  114  can be chamfered to prevent any cuts or scrapes when contacted. According to the example shown embodiment of  FIG. 11 , rail assembly  111  may have contoured surfaces on the interior facing portions of portion  110  proximate the water edge of the dock, and portion  112  on the interior facing wall of connecting portion  112 , while portion  110  farthest from the water edge of the dock remains planar, for example. As such rail  111  can be aligned substantially normally to the edge of dock  116 . To the portion proximate the waters edge of the dock can be coupled reflective material. 
         [0038]    In accordance with an example implementation, rail  111  may be utilized to assist during the docking of watercraft and/or rail  111  may be utilized to assist watercraft passengers during embarking and/or disembarking. According to example implementations, between a floating vessel and dock  116  a person may stabilize themselves with rail  111 . Upon stabilizing oneself, the person can transition between dock  116  and the floating vessel, for example. Rail  111  can be configured to extend from the upper surface of the dock without extending beyond the outer perimeter of the dock. An advantage of at least one embodiment of rail  111  is that it can allow a watercraft to approach a dock having rail  111  attached thereto without rail  111  damaging the exterior of the watercraft. 
         [0039]    According to another implementation, the vessel may be stabilized proximate dock  116 . As an example, a vessel occupant, upon approaching dock  116  may grasp rail  111  and retrieve the vessel toward or proximate dock  116 . 
         [0040]    Referring now to  FIGS. 12A through 12D , land-based applications of rail assembly  120  are shown. For example, a rail assembly  120  can be coupled to a substrate such as steps or a raised wall, for example, referring to  FIG. 12A .  FIG. 12B  is another view of assembly  120 .  FIG. 12C  is yet another embodiment of the assembly wherein the extending portions  110  are of different lengths, while the connecting portion  112  is connected at angles to extending portions  110  accommodating a rising step level. Interior surfaces of extending portions  110  can both be contoured while the interior portion of connecting portion  112  is contoured as well. Referring to  FIG. 12D , another embodiment of rail assembly  120  is shown wherein the rail assembly extends between more than one step. Accordingly, connection portion  112  may have a length that extends longer than extending portions  110  in such an embodiment.