Patent Publication Number: US-2022213691-A1

Title: Handrail, Kit, and Method for Installation of Same

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 16/376,805, filed Apr. 5, 2019, and the content of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to the field of handrails. The present invention relates specifically to handrails usable in behavioral health facilities. 
     In behavioral health facilities, some patients are at risk of harming themselves and will use whatever objects that may be around them to that effect. Thus, in behavioral health facilities, structures and components must be designed to substantially limit their ability to be used by patients who may wish to harm themselves. Embodiments of the present invention relate to a handrail system that addresses this need in the art. 
     SUMMARY OF THE INVENTION 
     One embodiment of the invention relates to a handrail kit. The handrail kit includes a cover, a first endcap, a second endcap, and a support member. The support member includes a longitudinal axis, a first end along the longitudinal axis, a second end along the longitudinal axis, a first lateral side, a second lateral side, a first longitudinal side, and a second longitudinal side. The first lateral side of the support member is configured to be secured directly against a mounting surface. The first endcap is configured to mate with the first end of the support member and the second endcap is configured to mate with the second end of the support member. The cover is configured to be placed over the second lateral side of the support member and to engage the first longitudinal side and the second longitudinal side of the support member. 
     Another embodiment of the invention relates to a method of installing a handrail. The handrail includes a first endcap, a second end cap, a support member, and a cover. The support member has a longitudinal axis, a first end along the longitudinal axis, a second end along the longitudinal axis, a first lateral side, a second lateral side, a first longitudinal side, and a second longitudinal side. In the method, the first endcap is mated to the first end of the support member, and the second endcap is mated to the second end of the support member. The first lateral side of the support member is attached directly to a mounting surface, and the cover is attached to the support member over the first longitudinal side and the second longitudinal side. 
     Another embodiment of the invention relates to a handrail. The handrail includes a support member having a longitudinal axis, a first end along the longitudinal axis, a second end along the longitudinal axis, a first lateral side, a second lateral side, a first longitudinal side, and a second longitudinal side. The handrail also includes a first endcap mated with the first end of the support member and a second endcap mated with the second end of the support member. Further, the handrail includes a cover placed over the second lateral side of the support member and engaged with the first longitudinal side and the second longitudinal side of the support member. The first lateral side of the support member is configured to be secured directly against a mounting surface. 
     Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which: 
         FIG. 1  depicts a perspective view of the handrail system, according to an exemplary embodiment; 
         FIG. 2  depicts a cross-sectional, perspective view of the handrail system of  FIG. 1  taken along line  2 - 2 ; 
         FIG. 3  depicts a cross-sectional view of the handrail system of  FIG. 1  taken along line  3 - 3 , showing the structural member and cover, according to an exemplary embodiment; 
         FIG. 4  depicts a perspective view of an endcap of the handrail system, according to an exemplary embodiment; 
         FIG. 5  depicts a cross-sectional view of the handrail system of  FIG. 1  taken along line  5 - 5 , showing the attachment of the endcap to the structural member, according to an exemplary embodiment; and 
         FIG. 6  depicts a cross-sectional view of the handrail system of  FIG. 1  taken along line  6 - 6 , showing the attachment of the structural member to the mounting surface, according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present invention is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting. 
     Generally, a handrail that is easier to install and more difficult to disassemble than conventional handrails is provided. In particular, the handrail includes a single piece support member that connects directly to the mounting surface (e.g., wall). The handrail cover snaps onto the support member in such a way that removal is difficult. In certain conventional designs, the handrail cover could be dislodged and used by a patient in a behavior health facility to harm himself/herself or others, or the patient could use the exposed handrail support member to injure himself/herself. Despite being more difficult to disassemble, the handrail is easier to assemble and install than other conventional designs, especially those requiring a backer board or mounting bracket to mount the support member to the wall. These and other advantages will be discussed in relation to the exemplary embodiments provided below. 
     Referring to the  FIG. 1 , an embodiment of a handrail  10  is depicted. As shown in  FIG. 1 , the handrail  10  is attached to a mounting surface  11 , such as a wall of a building. The handrail  10  includes a first endcap  12 , a second endcap  14 , and a handrail cover  16  that is disposed between the first endcap  12  and the second endcap  14 . The endcaps  12 ,  14  may also be referred to as “returns.” As can be seen in the embodiment depicted in  FIG. 1 , the endcaps  12 ,  14  and cover  16  define a substantially continuous surface along longitudinal axis a having corresponding curvatures going from the top of the handrail system  10  to the bottom of the handrail  10  (with respect to the orientation shown in  FIG. 1 ). In embodiments, the cover  16  and the endcaps  12 ,  14  are both comprised of a plastic material. In particular, the cover  16  and endcaps  12 ,  14  are preferably made from an impact resistant plastic. In an embodiment, the cover  16  is made from PVC. Further, in embodiments, the cover  16  is an extruded component. In embodiments, the endcaps  12 ,  14  are made from PVC or ABS. In embodiments, the endcaps  12 ,  14  are molded, e.g., injection molded, or made through additive manufacturing, e.g., 3D-printing. 
       FIG. 2  provides a perspective and partial-sectional view of the handrail  10 , showing the rear, wall-facing side of the handrail  10 . As can be seen in  FIG. 2 , the cover  16  is snapped over a handrail support member  18 , which will be discussed in more detail in relation to  FIG. 3 . Additionally, the endcap  14  engages an end of the handrail support member  18  as will be discussed more fully below in relation to  FIG. 4 . 
     Turning to  FIG. 3 , a cross-sectional view of the support member  18  and the cover  16  taken along the longitudinal axis a is shown. In embodiments, the support member  18  is made from extruded aluminum. Advantageously, each of the structure shown in the cross-sectional view of  FIG. 3  and that will be discussed below can be formed directly in the extrusion process. In other embodiments, the support member  18  can be made from another material, such as another metal or a plastic. The support member  18  has a central strip  20  that, when installed, is substantially parallel to the mounting surface. Extending substantially perpendicularly from a first lateral side of the central strip  20  that faces the mounting surface is a mounting arm  22 . Also extending from the first lateral side of the central strip  20  is an angled mounting arm  24 . In embodiments, the angled mounting arm  24  is angled relative to the central strip  20  at an angle of, e.g., from 91° to 135°. At the end of the mounting arm  22  is a first mounting strip  26 , and at the end of the angled mounting arm  24  is a second mounting strip  28 . The mounting strips  26 ,  28  are configured to abut the mounting surface when installed. 
     A first support arm  30  and a second support arm  32  extend away from the second lateral side of the central strip  20  that faces away from the mounting surface. As shown in  FIG. 3 , the first support arm  30  is in line with the mounting arm  22  such that the central strip  20 , mounting arm  22 , and first support arm  30  form a junction in the support member  18 . As is also shown in  FIG. 3 , the second support arm  32  is in line with the place where the angled mounting arm  24  extends from the central strip  20  such that the central strip  20 , angled mounting arm  24 , and second support arm  32  also form a junction in the support member  18 . The support arms  30 ,  32  are designed to provide support for the cover  16  so that the cover  16  maintains its contour when installed on the support member  18 . In furtherance of this function, a first support panel  34  is disposed at an end of the first support arm  30 , and a second support panel  36  is disposed at an end of the second support arm  32 . As can be seen in  FIG. 3 , the support panels  34 ,  36  are angled relative to the support arms  30 ,  32  to match the contour of the cover  16  in the region in which the cover  16  contacts the support panels  34 ,  36 . 
     On a first longitudinal side, the central strip  20  also includes a curved extension  38 . With respect to the orientation of the central strip  20  shown in  FIG. 3 , the curved extension  38  extends upwardly from the central strip  20 . Further, in embodiments, the curved extension  38  curves toward the mounting surface. Proximal to a distal end of the curved extension  38  is a first projection  40 . The first projection  40  extends substantially perpendicularly from the curved extension  38 . At the end of the first projection  40  is a curved support section  42  creating a curved surface over which the cover  16  is supported. The curved extension  38 , first projection  40 , and curved support section  42  create a slot  44  into which the cover  16  terminates. In particular, the cover  16  includes a first curved section  46  having a curvature that substantially matches the curvature of the curved support section  42  and that hooks over the curved support section  42 , and a first edge  48  of the cover  16  terminates in the slot  44 . In embodiments, the curved extension  38  has a tapered surface  50  designed to match the curvature of the cover  16  in the region where it enters the slot  44 . By terminating the cover  16  in the slot  44 , a patient cannot easily grip the first edge  48  to try to pry to the cover  16  from the support member  18 . 
     On a second longitudinal side of the support member  18  opposite to the curved extension  38  is a depending extension  52 . Depending extension  52  is substantially in line with the central strip  20 . A second projection  54  extends from an end of the depending extension  52  in the second lateral direction and toward the cover  16 . Further, extending from the second projection  54  is a ledge  56 . A protrusion  58  juts from a surface of the ledge  56  that faces the mounting surface. As shown in  FIG. 3 , the cover  16  includes a second curved section  60  with a second edge  62 . The second curved section  60  is configured to slide over the front face of and around the ledge  56  such that the second edge  62  abuts or is in close proximity to the protrusion  58 . Similar to the slot  44  into which the first edge  48  terminates, the proximity of the protrusion  58  and the second edge  62  makes gripping the second edge  62  more difficult, especially for the purpose of prying the second curved section  60  from around the ledge  56 . Together, curved support section  42 , projection  40 , curved extension  38 , central strip  20 , depending extension  52 , projection  54 , ledge  56 , and protrusion  58  define a base member of support member  18 . As shown in  FIG. 3 , when installed, cover  16  engages the first side of the base member, facing the mounting wall, at a first location that is beneath mounting arms  22 ,  24 , covers the second side of the base member, facing away from the mounting, and engages the first side of the base member at a second location that is above mounting arms  22 ,  24  and within slot  44 . 
     Between the first curved section  46  and the second curved section  60  of the cover  16  is a contoured section  64 . The contoured section  64  can be of any of a variety of suitable contours available for handrail designs. As mentioned above, the support panels  34 ,  36  maintain the contour of the contoured section  64 . Further, in embodiments, the cover  16  is formed in such a way and from such a material that the cover  16  has to be flexed to fit it over the curved support section  42  and the ledge  56 . In this way, the cover  16  will be in tight engagement with the curved support section  42 , the support panels  34 ,  36 , and the ledge  56 . Advantageously, the tight engagement diminishes any wiggle room or play between the cover  16  and the support member  18 , which might be exploited to facilitate removal of the cover  16  from the support member  18 . 
     With reference now to  FIG. 4 , endcap  12  is depicted. Endcap  14  is substantially similar to endcap  12  but is a mirror inverse structure. Thus, discussion of endcap  12  applies as well to endcap  14 . The endcaps  12 ,  14  are configured to mate with the support member  18 . Additionally, like support member  18 , the endcaps  12 ,  14  are configured such that the cover  16  locks into the endcaps  12 ,  14  in a manner that makes removal of the cover  16  difficult. Thus, as shown in  FIG. 4 , the endcap  12  includes an engagement section  66  having a slot  68  formed by a curved extension  70  and a curved support section  72 . As with the support member  18  of  FIG. 3 , the first edge  48  of the retainer cover  16  terminates in the slot  68 . In embodiments, the curved extension  70  includes a tapered surface  72  designed to match the curvature of the cover  16  in the region where it enters the slot  68 . As shown in  FIG. 1 , when cover  16  is coupled to endcap  12  and support member  18 , the outer surface of cover  16  aligns substantially flush with the outer surface of endcap  12  where the outer surface of cover  16  abuts the outer surface of endcap  12 . 
     Further, the endcap  12  also includes a contoured ridge  74  that extends substantially perpendicularly from a side surface  76  of the endcap  12 . The contoured ridge  74  is similar in function to the support panels  34 ,  36  and to the ledge  56  of the support member  18  as shown in  FIG. 3 . That is, the contoured ridge  74  supports the contoured section  64  of the cover  16  and provides a structure for the second edge  62  of the cover  16  to slide over and around. Thus, the contoured ridge  74  extends along the side surface  76  from a location proximal to the curved extension  70  downwardly to the bottom (with respect to the orientation shown in  FIG. 4 ) of the endcap  12  and curves toward the mounting surface and then back upwardly to form a central ridge  78 , leading to the curved extension  70  and curved support section  72 . As with the ledge  56  shown in  FIG. 3 , a protrusion  80  extends from a portion of the central ridge  78  proximal to where the contoured ridge  74  turns upwardly on the endcap  12 . The second edge  62  abuts or is in close proximity to the protrusion  80 , which makes gripping the second edge  62  more difficult, especially for the purpose of prying the second curved section  60  of the cover  16  from around the contoured ridge  74  of the endcap  12 . 
     The endcap  12  includes multiple structures configured to engage the support member  18 . Extending from the side surface  76  of the endcap  12  are a first plank  82  and a second plank  84 . The first plank  82  extends from a first side of the central ridge  78 , and the second plank  84  extends from a second side of the central ridge  78 . In this way, the planks  82 ,  84  are separated by at least a distance corresponding to the thickness of the central ridge  78 . In this way, the planks  82 ,  84  define a slot  86  adapted to receive the central strip  20  of the support member  18 . During installation, one or more holes are drilled (or may be pre-drilled) through the planks  82 ,  84  and the central strip  20 , and a fastener (e.g., a self-tapping screw) is inserted through each hole to join the endcap  12  to the support member  18 . 
     The endcap  12  includes an interior surface  88  from which a first panel  90  extends. The first panel  90  is arranged substantially perpendicularly to the central ridge  78 . Also extending from the interior surface  88  of the endcap  12  is an angled second panel  92 . The first panel  90  and the second panel  92  are joined by a mounting panel  94  that is arranged substantially perpendicularly to the first panel  90 . Upon installation, the mounting panel  94  abuts the mounting surface. The first mounting panel  90  includes a first lip  96 , and the second mounting panel  92  includes a second lip  98 . The lips  96 ,  98  are positioned such that they insert between the mounting arm  22  and the angled mounting arm  24  of the support member  18  and such that the first panel  90  forms a substantially continuous surface with the mounting arm  22  and such that the second panel  92  forms a substantially continuous surface with the angled mounting arm  24  (e.g., as shown in  FIG. 2 ). 
     As can be seen in  FIG. 4 , the endcap  12  has an arcuate structure. Specifically, the endcap  12  has a degree of curvature of about 90°. In this way, the endcap  12  caps the cover  16  and support member  18 , which are arranged parallel to the mounting surface, and transitions the end of the handrail system  10  into the wall. However, in other embodiments the endcaps  12 ,  14  can instead be inside or outside corners that join sections of the handrail system  10 . That is, where two mounting surfaces meet, a first support member  18  and cover  16  can be installed on one mounting surface  11 , and a second support member  18  and cover  16  can be installed on the other mounting surface  11 . The two sections can be joined at the corner where the mounting surfaces meet, e.g., an inside corner where the angle between the mounting surfaces  11  is less than 180° or an outside corner where the angle between the mounting surfaces  11  is greater than 180°. The endcap  12  or endcap  14  will be angled to match the angle of the inside or outside corner and will have two engagement sections  66  at opposite ends of the endcap  12  or  14  to facilitate connection to both sections of the handrail system  10 . 
     As mentioned above, the handrail system  10  as described herein is simpler to install than other conventional designs. In order to install the handrail system  10  on a mounting surface  11 , the endcaps  12 ,  14  may first be attached to the support member  18 . As shown in  FIG. 5 , the planks  82 ,  84  are placed on either side of the central strip  20 , and a fastener  100 , such as a self-tapping screw, is inserted through the planks  82 ,  84  and central strip  20 . In embodiments, the endcaps  12 ,  14  are only attached to the support member  18  and are not otherwise attached to the mounting surface  11 . However, in other embodiments, the mounting panel  94  may be provided with an adhesive or bonding agent to attach the endcap  12 ,  14  to the mounting surface  11  in addition to being secured to the support member  18 . After securing the endcaps  12 ,  14  to the support member  18 , the support member  18  is connected to the mounting surface  11  as shown in  FIG. 6 . A fastener  104  is inserted through a hole in the central strip  20  of the support member  18 . The hole may be drilled at the time of installation or the hole may be predrilled. The fastener  104  is then secured to a threaded structure  106  in the mounting surface  11 . In the embodiment depicted, the threaded structure  106  is a threaded insert embedded, e.g., into a wall stud. In other embodiments, the threaded structure  106  can be a drywall anchor, a toggle bolt, a molly, etc. The number of fasteners  104  used to secure the support member  18  to the mounting surface  11  will depend, at least in part, on the length of the support member  18 . For example, a fastener  104  may be placed every two to six feet along the length of the support member  18  to secure the support member  18  to the mounting surface  11 . While the installation method described involves attaching the endcaps  12 ,  14  to the support member  18  prior to attaching the support member  18  to the mounting surface  11 , in other embodiments the endcaps  12 ,  14  can be attached after the support member  18  after attaching the support member  18  to the mounting surface  11 . 
     Once the support member  18  and endcaps  12 ,  14  are secured to the mounting surface  11 , the cover  16  is snapped onto support member  18  and endcaps  12 ,  14 . In an embodiment, the second edge  62  of the second curved section  60  of the cover  16  is hooked under the ledge  56  such that the second edge  48  abuts or is in close proximity to the protrusion  58  of the ledge  56 . The first edge  48  of the first curved section  46  is then flexed over the curved support section  42  such that the first edge  48  of the first curved section  46  is inserted into the slot  44 . As the first edge  48  slides into the slot  44 , the cover  16  recovers from its flexed state to a relaxed state, which provides tight conformance of the cover  16  to the support member  18  and the endcaps  12 ,  14  and completes the installation. 
     Thus, the installation of the handrail system  10  can be completed in three steps: (1) attaching the endcaps  12 ,  14  to the support member  18 ; (2) attaching the support member  18  to the mounting surface  11 ; and (3) attaching the cover  16  to the support member  18 . Further, a basic installation only requires four components: the two endcaps  12 ,  14 , the support member  18 , and the cover  16 . Conventional handrail designs often require additional steps and a greater number components for the installation. For example, many handrail designs require a mounting bracket be installed on the wall. In such designs, a retainer strip for the endcaps and cover is provided and attached to the mounting bracket. Thus, these designs incorporate at least one additional component and an additional installation step. 
     In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions and angles of the various exemplary embodiments. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
     Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.