Patent Publication Number: US-8990973-B2

Title: Grab bar assembly

Description:
TECHNICAL FIELD 
     This invention relates to a bar that is utilized in bathrooms, such as a grab bar for example, and more specifically the invention relates to a non-linear grab bar configuration. 
     BACKGROUND OF THE INVENTION 
     Grab bars are utilized in bathroom applications to provide support for an individual during exit or entry in a bathtub or shower, for example. Typical grab bars include a linear/straight body member that is spaced apart from, and parallel to, a wall. The grab bar has end mounts that extend toward the wall such that the grab bar can be mounted to the wall. In some configurations, the linear/straight body member may include straight angled portions such that the grab bar can be gripped at different orientations. 
     The most traditional overall shape of the body member is a single straight linear shape that extends between two mounting points. Optionally, the body member includes a first linear portion and a second linear portion extending at a different angle relative to the first linear portion to form a “V-shape” or L-shape.” For example, the first linear portion can comprise a horizontally extending portion and the second linear portion can comprise a vertically extending portion, with one mounting point being located at one end of the horizontally extending portion and a second mounting point being located an opposite end of the vertically extending portion. 
     One disadvantage with these traditional linear configurations is that they are institutional in appearance. For use in hotels, homes, and other non-institutional-type environments, it is often desirable to have a grab bar that presents an aesthetically appealing appearance. However, configurations deviating from a linear configuration are challenging because they must be able to be easily installed and meet all industry standards, as well as being economical to produce. 
     SUMMARY OF THE INVENTION 
     A grab bar for a bathroom is configured to have a grab bar body with an overall shape that is defined by an inner peripheral surface and an outer peripheral surface. The grab bar body defines an open center space that is entirely bounded by the inner peripheral surface. 
     In one example, the grab bar body has an overall shape that corresponds to an oval shape, with the open center space having a corresponding oval shape. 
     In one example, the grab bar body has a circular cross-section. The grab bar body is formed from an extrusion, such as an aluminum extrusion for example, that has a hollow tubular shape. The extrusion is bent into a desired overall shape, such as an oval shape for example. 
     In one example, the grab bar body is formed from first and second pieces. The first piece comprises a flexible piece that is made from injection molded plastic, for example. The second piece comprises a rigid piece that is made from cast aluminum for example. In one configuration, the flexible piece is positioned to be closest to a wall structure and the rigid piece forms a front facing piece that facing opposite the wall structure. The rigid and flexible pieces are secured together via at least one mount interface. Mount assemblies are used to secure the grab bar body to the wall structure. 
     The subject grab bar provides a grab bar body having an aesthetically pleasing, non-linear, overall shape that can be easily installed, satisfies industry standards, and which is economical to produce. These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a grab bar assembly. 
         FIG. 2  is an exploded view of the grab bar assembly of  FIG. 1 . 
         FIG. 3  is a partial perspective view of first and second pieces used to form a grab bar body as shown in  FIG. 2 . 
         FIG. 4  is a cross-sectional view of the grab bar body. 
         FIG. 5  is a perspective view of a portion of one grab bar body piece at a mount interface. 
         FIG. 6  is a schematic cross-sectional view of a mounting post as installed in the first and second pieces. 
         FIG. 7  is a perspective view similar to that of  FIG. 6  but showing the mounting post in an uninstalled position. 
         FIG. 8  is a cross-sectional view of another example of a grab bar body. 
         FIG. 9  is a perspective view of a mount interface for the grab bar body of  FIG. 8 . 
         FIG. 10  is an exploded view of a grab bar assembly for the grab bar body of  FIG. 8 . 
         FIG. 11  is a cross-sectional view of the mount interface of  FIG. 9 . 
         FIG. 12  shows mating end faces of first and second collar pieces. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A grab bar assembly  10  for attachment to a bathroom wall structure, such as a wall  12  of a tub or shower is shown in  FIG. 1 . The grab bar assembly  10  includes a grab bar body  14  with an overall shape that is defined by an inner peripheral surface Pi and an outer peripheral surface Po that is radially spaced from the inner peripheral surface Pi. The grab bar body  14  defines an open center space  16  that is entirely bounded by the inner peripheral surface Pi. 
     As such, the grab bar body  14  is configured to have looped or ring configuration, i.e. a non-linear shape. In the example shown in  FIG. 1 , the grab bar body  14  has an overall shape that is oval with a corresponding open center space that is oval; however other bounded shapes could also be formed by the grab bar body  14 . For example, the grab bar body could be configured to have a triangular shape or square/rectangular shape, with corresponding open spaces that would be triangular or square/rectangular shape. 
     Mounting assemblies  18  are used to secure the grab bar body  14  to the wall structure  12 . In the example shown in  FIG. 1 , two mounting assemblies  18  are shown; however, it should be understood that a single mounting assembly could be used, or additional mounting assemblies could be used, depending upon the overall configuration of the grab bar assembly. 
     In this example configuration, the grab bar body  14  comprises a clamshell design where first  20  and second  22  pieces are secured together to create a desired overall shape, which in this example is an oval shape. Due to load bearing requirements defined by industry standards, this shape would not have been possible using a traditional bent, formed, and welded extrusion. This is due to the thick wall sections that would be required for load bearing purposes, and the fact that in forming non-circular sections there is material displacement that causes cracks and unappealing surface defects. To avoid these problems, and to provide the desired overall shape, the grab bar body  14  uses a two-piece configuration. 
     In the example shown, the first piece  20  comprises a hollow inner piece that is closest to the wall structure  12  and the second piece  22  comprises a hollow outer piece that provides a front viewable face that faces opposite from the wall structure  12 . The first  20  and second  22  pieces are made from different materials and are made using different forming methods. The first piece  20  comprises a flexible structure and the second piece  22  comprises a rigid structure. 
     In one example, the second piece  22  is made from a structural material, which is used to handle load bearing requirements. For example, the second piece  22  could be made from cast aluminum; however, other suitable rigid/structural materials could also be used. In one example, the first piece  20  is made from an injection molded plastic such that the first piece  20  provides some flexibility for alignment and adjustment purposes. The first piece  20  is decorative in nature and does not perform load bearing functions, thus use of a plastic material helps to reduce the overall cost of the grab bar assembly  10 ; however, other suitable flexible materials could also be used. 
     Due to the use of two different materials to form the grab bar body  14 , an interlocking feature is required to align the first  20  and second  22  pieces relative to each other. The interlocking feature is required to prevent perimeter walls of the first  20  and second  22  pieces from becoming misaligned during assembly, which would cause a step formation between the two pieces. The interlocking feature will be discussed in greater detail below. 
     Additionally, it is important to have proper alignment between the grab bar body  14  and the mounting assembly  18 . Alignment at this interface is important such that loads are fed through a defined path to ensure predictable performance results. 
     The mounting assembly  18  is shown in greater detail in  FIG. 2 . The mounting assembly includes a base flange  26  with an o-ring  28 , a fastener  30  and washer  32  that is installed through a center bore  34  in the base flange  26 , and a post assembly  36 . The post assembly  36  provides an interface to the first  20  and second  22  pieces and includes a post sleeve  38 , a fastener  40 , and an associated washer  42 . A set screw  44  is used to secure the base flange  26  to the post sleeve  38 . 
     Fasteners  46  are used to secure the first  20  and second  22  pieces to each other. Four (4) such fasteners  46  are shown in  FIG. 2 . It should be understood that fewer or additional fasteners could be used depending upon the overall shape and size of the grab bar body  14 . Caps  48  are used to cover heads of the fasteners  46  when installed. 
     The interlocking feature for the first  20  and second  22  pieces is shown in greater detail in  FIG. 3 . The interlocking feature includes two different mounting interfaces. As discussed above, the first piece  20  comprises a hollow structure and includes a general C-shape configuration with an inner base surface  50  having first  52  and second  54  walls extending outwardly from the base surface  50  to form a C-shape. The second piece  22  also comprises a hollow structure having a general C-shape configuration. As such, the second piece  22  includes an inner base surface  56  and first  58  and second  60  walls extending outwardly from the inner base surface  56  to form the C-shape. The first  52  and second  54  walls of the first piece  20  are aligned with the first  58  and second  60  walls of the second piece  22 . 
     To assist in initial alignment of the first  20  and second  22  pieces, the second piece  22  includes a plurality of threaded posts  62  that extend slightly beyond a wall height of the second piece  22 . Each threaded post  62  is supported on opposing sides by ribs  64 . Each rib  64  extends from an outer surface of the threaded post  62  to contact one of the first  58  and second  60  walls. The first piece  20  includes a counter bore  66  for each of the threaded posts  62 . The counter bores  66  do not include ribs like those associated with the threaded posts  62 . As such the counter bores  66  are free-standing with air gaps formed between an outer surface of each counter bore  66  and the first  52  and second  54  walls. This facilitates the flexibility of the first piece  20  to ensure self-alignment between the first  20  and second  22  pieces. The fasteners  46  are inserted through the counter bores  66  and are threaded into the threaded posts  62  to secure the first  20  and second  22  pieces together. Thus, the threaded posts  62 , counter bores  66 , and fasteners  46  form one of the mounting interfaces for the interlocking feature. 
     The other mounting interface for the interlocking feature includes a groove and rib configuration. The first  20  and second  22  pieces each define a portion of the inner peripheral surface Pi and the outer peripheral surface Po. The first  52  and second  54  walls of the first piece  20  each have a groove  70  formed within a distal end face of the walls. The grooves  70  extend peripherally about the first  52  and second walls  54  as shown. The first  58  and second  60  walls of the second piece  22  each have a rib  72  formed within a distal end face of the walls. The ribs  72  extend peripherally about the first  58  and second  60  walls similar to that of the grooves  70 . 
     When the fasteners  46  are inserted through the counter bores  66  and threaded into the threaded posts  62  to assemble the first  20  and second pieces together, the ribs  72  on the second piece  22  align with the corresponding grooves  70  on the first piece  20 . Any slight deformation in the first piece  20  is compensated for by the self-centering features, which comprise the grooves  70  and ribs  72 . 
     In one example, the grooves  70  and ribs  72  have corresponding triangular shapes, see  FIG. 4 . This basic shape provides a finite point at which the first  52  and second  54  walls of the first piece  20  will seek the center of the first  58  and second  60  walls of the second piece  22 . Flexibility of the first piece  20  for this purpose is indicated by arrows  74  in  FIG. 4 . 
     It should be understood that while threaded posts  62  are shown on the second piece  22  and counter bores  66  are shown on the first piece  20 , the reverse configuration could also be used with the bores being located in the second piece and the posts being located in the first piece. Further, a reverse configuration for the groove and rib configuration could also be used, with grooves formed in the second piece and ribs formed in the first piece. 
     One advantage of using ribs  72  in the second piece  22  relates to the casting method used to form the second piece  22 . When ribs are formed in the first piece and grooves are formed in the second piece, which is the reverse configuration to that shown in  FIG. 3 , casting difficulties result. A significant number of defects can be produced when the casting (second piece) is separated from a feeder and gate material. Gates have to be located at edges of the casting, which makes it difficult to avoid breaking off material that is not intended to be removed, consistently resulting in castings with gaps or voids around the parting line between the two pieces. 
     In the configuration shown in  FIGS. 3 and 4 , the ribs  72  are formed within end faces of the walls  58 ,  60  of the second piece  22 . Gates are located at an apex of the triangular shaped rib  72 , as indicated at  76 . By positioning the gates at the apex, they are easily removed and any extra material that is removed will not be seen as it will be internally hidden within the assembly. Thus, it is advantageous from a manufacturing aspect to form the ribs  72  in the second piece  22  and the grooves  70  in the first piece  20 . 
     As discussed above, it is also important to provide accurate positioning between the post sleeve  38  relative to the second piece  22 . Accurate positioning of the post sleeve  38  ensures that loads will be focused through a defined path to provide predictable and consistent performance results. For each mounting assembly  18 , the second piece  22  includes a pair of alignment tabs  80  as shown in  FIG. 5 . The tabs  80  have tapered outer edges that interface with an inner surface  82  of the post sleeve  38  ( FIG. 6 ), which maintains accurate position of the post sleeve  38  during assembly. 
     Between the tabs  80  a post  84  with a threaded bore  86  is provided. The post  84  is received within a first recess  88  formed within the post sleeve  38 . The tabs  80  are received within a second recess  90  that is radially spaced outward relative to the first recess  88 . Walls  92  separate the first  88  and second  90  recesses. The fastener  40  and associated washer  42  are inserted through an opening  94  in the post sleeve  38  and into the threaded bore  86  to secure the post sleeve  38  to the second piece  22 . 
     The post sleeve  38  is also used to clamp the first piece  20  to the second piece  22 . By adding material to the first piece  20  at a point where the post sleeve  38  interfaces with the first piece  20 , clamping pressure generated by attachment of the post sleeve  38  to the second piece  22  can be used advantageously. A post support  96  ( FIGS. 5 and 7 ) is formed with the second piece  22 . The post support  96  is comprised of a pair of arcuate portions that are separated from each other, i.e. the post support  96  does not form a complete circle. A corresponding shape with two surfaces  98  is formed within the first piece  20 . These surfaces  98  can withstand the clamping pressure without interfering with the solid interface between the post sleeve  38  and the post support  96 . 
     To maintain the correct position of the post sleeve  38  to the first  20  and second  22  pieces, a small notch  100  is formed within the post sleeve  38 , as shown in  FIG. 7 . The notch  100  interfaces with a rib  102  that is formed on one of the surfaces  98  of the first piece  20  ( FIG. 7 ). 
     Another example of a grab bar assembly  200  is shown in  FIGS. 8-12 . This example is similar to that of  FIGS. 1-7  in that a grab bar body  202  has an overall shape that is oval, triangular, square, etc. as discussed above. However, in this example, the grab bar body  202  is formed from a single piece instead of comprising a two-piece design. 
     The grab bar body  202  is comprised of an extrusion that is circular and hollow in cross-section as shown in  FIG. 8 . An aluminum material or other suitable material can be used to form the extruded component. As such, the grab bar body  202  is first formed as a tube, which is then easily bent and formed into a desired overall shape, such as an oval shape for example. The grab bar body  202  has an inner peripheral surface Pi and an outer peripheral surface Po that is spaced radially outward relative to the inner peripheral surface Pi. As such, an open center space  204  is provided that is entirely bounded by the inner peripheral surface Pi. A shape of the open center space  204  corresponds generally to the overall shape of the grab bar body  202 . 
     To create an oval shape, the tube is first formed into a circle, and then abutting ends are butt-welded to form a ring or donut shape. The ring is then reformed to create the oval shape. Mounting assemblies  206  are used to secure the grab bar body  202  to a wall structure  208 . It should be understood that while two mounting assemblies  206  are shown for the configuration set forth in  FIGS. 8-12 ; fewer or additional mounting assemblies could be used as needed. 
     The mounting assemblies  206  each include three main components: a first collar piece  210 ; a second collar piece  212 ; and a base flange  214 . To reduce overall tooling costs, one main casting die is used for each of these components. These individual dies have interchangeable design elements that are simple inserts  216  that can be removed or added as needed for a particular design configuration. In the example shown in  FIG. 9 , a beaded insert  216  is shown; however, this could be easily replaced with another patterned insert for a different look. Thus, new looks can be created without significant additional tooling costs. 
     Industry standards require that the grab bar body  202  cannot rotate within associated fixing points, which are located at the mounting assemblies  206 . A collar assembly including the first  210  and second  212  collar pieces is used that closely follows a trajectory of a grab bar path. This provides a consistent gap between the grab bar and the collars. 
     As shown in  FIG. 10 , the first collar piece  210  includes a sleeve portion  218  that interfaces with the base flange  214 . A set screw  220  is used to secure the sleeve portion  218  to the base flange  214 . The first collar piece  210  is associated with a wall facing side  222  of the grab bar body  202 , while the second collar piece  212  is associated with a front facing side  224  of the grab bar body  202 . 
     In order to hold the grab bar body  202  securely in place within the fixing points, the second collar piece  212  includes an internally threaded post  226  that is of sufficient length to pass entirely through both sides of the grab bar body  202  and that receives threaded fastener  244 . A washer  246  is associated with the fastener  244 . A distal end  228  of the threaded post  226  is then press-fit into an opening  230  in the first collar piece  210  ( FIG. 11 ). The press-fit interface is needed to satisfy industry standards for load bearing requirements. 
     To accommodate for normal manufacturing tolerances, any remaining space between the grab bar body  202  and the collar pieces  210 ,  212  is taken up by a resilient washer  232 . A fastener  234  and washer  236  extend through the base flange  214  to secure the grab bar assembly  200  to the wall structure  208 . An o-ring  238  is associated with the base flange  214  to provide a sealed interface. 
     Alignment between the second collar piece  212  and the first collar piece  210  is controlled by the use of dome features  240  that engage into corresponding socket features  242 . In the example shown, four of each of these features is used; however other numbers could also be used. To assist in manufacturing and assembly, the dome  240  and socket  242  features are positioned such that they only have one way in which they will correctly align. This is achieved by positioning both sockets and domes on the same collar piece and reversing the detail for the mating component. This feature is of particular importance when the trajectory is a very large radius and resembles a straight line at a glance. 
     In the example shown in  FIGS. 11-12 , the second collar piece  212  includes two dome features  240  (one is shown in  FIG. 11 ) and two socket features  242  (one is shown in  FIG. 11 ). The first collar piece  210  also includes two dome features  240  (only one is shown in  FIG. 11 ) and two socket features  242  (only one is shown in  FIG. 11 ). 
     The dome features  240  and socket features  242  cooperate to prevent the first  210  and second  212  collar pieces from rotating and becoming misaligned with respect to each other. Once tightened, there may be some space between the grab bar body  202  and the collar pieces  210 ,  212 . This additional space is taken up by the resilient washer  232 . 
     Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.