Abstract:
A method of assembling a towel rail having vertically extending, elongate, tubular supports opposed and spaced apart from each other, and spaced apart, horizontally extending, tubular beams, the method including: a) threading an elongate flexible heating element through a respective support; b) looping an appropriate length of the element through each hole of the support to form a plurality of looped sections; c) threading each looped section through a respective beam from the second end; d) inserting the second end of each beam through a respective hole of the respective support to bring an abutment surface of the second end into contact with an inner surface of the support; and e) locking the second end of each beam to the support by passing a fastener at least partially through the support to engage with a recess formed in the second end.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a towel rail such as a heated towel rail which is manufactured from stainless steel tubes as well as a method of manufacturing thereof. 
     It is known to manufacture heated towel rails from a plurality of horizontal beams which are welded to one or more vertical posts. It is difficult, cumbersome and expensive to obtain a neat weld between the respective beams and each support. 
     As towel rails often fulfill both practical and aesthetic functions it is important that the finished product is neatly finished with clean lines and junctions. 
     SUMMARY OF THE INVENTION 
     The invention aims to provide an alternative towel rail and a method of manufacturing thereof. 
     The invention provides a towel rail which includes at least one vertically extending, elongate, tubular support, a plurality of spaced apart, horizontally extending, tubular beams which extend from the support, each of which has a first end and an opposing second end, a first recess formed in the first end and a second recess formed in the second end and a plurality of fasteners, each of which extends at least partially through the support and which is engaged with a recess. 
     Preferably the towel rail includes two opposing and spaced apart supports. 
     The support and beams may be circular in cross-section, or may be rectangular in cross-section. The support and beams may be made from metal and is preferably made from stainless steel. 
     Each of the first and second ends may include an abutment surface which abuts against a support. The abutment surface may be semicircular and complementary in shape to the support. Alternatively the abutment surface may include two spaced apart abutment points. 
     Each of the first and second ends may include a shoulder formation. 
     Each of the first and second ends may include a spacer which extends from the respective beam. 
     Each beam may include a first opening in the first end which faces in a first direction. The first opening may include a catch formation. Each beam may include a second opening in the second end which faces in a second direction which is opposed to the first direction. Each of the first and second openings may be in the form of a slot. 
     Each fastener may be in the form of a grub screw or a bolt. 
     The towel rail may include a plurality of apertures in the support through which the fasteners extend. 
     The towel rail may include an attachment bracket which is engaged with the support and which is used to fix the support to fixed structure. 
     The towel rail may include a connection means between the attachment bracket and the support. 
     The connection means may include a tubular arm which is fixed to the bracket and a flange formation which extends from the support. The connection means may include a hook formation on the arm and a recessed catch formation in the support with which the hook formation is interengageable. The flange is preferably integrally formed with the support. The connection means may include a securing member which interconnects the arm and the flange formation. 
     The towel rail may include a passage which extends from the support, through the connection means to the bracket. 
     The towel rail may include an elongate heating element which extends at least partially through the support and the beams. 
     The invention also provides a method of manufacturing a towel rail which includes the steps of:
     (a) cutting a plurality of holes in an elongate, tubular metallic support;   (b) forming a first recess in a first end of an elongate, tubular, metallic beam and forming a second recess in a second opposing end of the beam;   (c) engaging a plurality of beams with the support by engaging the first end of each beam with a respective hole; and   (d) fixing the support and each beam to one another by passing a fastener through the support and engaging the fastener with the first recess.   

     The method may include the step of forming an aperture in the support where through the fastener can extend. 
     The method may include the step of cutting a first opening in the first end which faces a first direction. The method may include the step of cutting a second opening in the second end which faces a second direction which is opposite to the first direction. 
     The method may include the step of shaping the first and second ends to be complementary with an inner side of the support. Each of the first and second ends may be shaped to be semicircular. 
     Alternatively the method may include the step of forming two, spaced apart abutment points on each of the first and second ends. 
     The method may include the step of forming a shoulder formation on each of the first and second ends. 
     The method may include the step of cutting a spacer formation from each of the first and second ends in order for the spacer formation to remain integral with the beam. 
     The method may include the step of threading an elongate, flexible heating element at least partially through the support and beams. 
     The method may include the step of fixing a bracket to the support. 
     The method may include the step of cutting a flange from the support which extends from the support and is integrally formed with the support. 
     The method may include the step of fixing an arm which extends from the bracket to the flange. 
     The method may include the step of interengaging a hook formation which is formed on the arm with a catch formation in the support. 
     The invention further provides a towel rail which has at least one vertically extending, elongate, tubular support, a plurality of horizontally extending, elongate, tubular beams which extend from the support, at least one attachment bracket which is fixed to the support and a connection means between the bracket and the support which has a tubular arm which is connected to the bracket, a flange formation which extends from and is integrally formed with the support and a securing member which interconnects the arm and the flange. 
     The connection means may include a hook formation on the arm and a recessed catch formation in the support which hook formation and catch formation are interengaged. 
     The towel rail may include a passage which extends from the support, through the connection means and to the bracket. 
     The towel rail may include an elongate, flexible heating element which extends through the passage. 
     The invention also extends to a method of fixing a bracket to a towel rail which has a vertically extending, elongate, tubular support which includes the steps of:
     (a) cutting a flange formation in the support;   (b) bending the flange formation away from the support in order for the flange formation to extend away from the support while remaining integral with the support;   (c) cutting a catch formation in the support; and   (d) interconnecting a tubular arm which extends from the bracket with the flange formation and interengaging a hook formation on the arm with the catch formation.   

     The cutting of the flange formation and the catch formation in the support may take place simultaneously. 
     The method may include the step of fixing a securing member to the arm and the flange formation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention is further described by way of examples with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view of a towel rail according to the invention; 
         FIG. 2  is a partial, cross-sectioned side view of the towel rail of  FIG. 1 ; 
         FIG. 3  is a partial, cross-sectional view from above of the towel rail of  FIG. 1 ; 
         FIG. 4  is a partial, cross-sectional view from above of an alternative towel rail according to the invention; 
         FIG. 5  is a perspective view of another towel rail according to the invention; 
         FIG. 6  is a partial, cross-sectional side view of the towel rail of  FIG. 5 ; 
         FIG. 7  is a partial, cross-sectional view from above of the towel rail of  FIG. 5 ; 
         FIG. 8  is a partial, cross-sectional view from above of a further towel rail according to the invention; 
         FIG. 9  is a partial, cross-sectional side view of yet another towel rail according to the invention; 
         FIG. 10  is a partial, cross-sectional side view of the towel rail of  FIG. 9 ; 
         FIG. 11  is a partial, cross-sectional side view of a bracket connection used in the towel rail of  FIG. 4 ; 
         FIG. 12  is a partial, cross-sectional side view of the connection of  FIG. 11 ; and 
         FIG. 13  is a partial, cross-sectional view from above of the connection of  FIG. 11 . 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       FIGS. 1 ,  2  and  3  illustrate a towel rail  10  which has a first vertically extending, elongate, tubular support  12 , a second vertically extending, elongate, tubular support  14  which is spaced from the first support  12  and which opposes the first support  12 , a plurality of horizontally extending, elongate, tubular cross beams  16 , each of which extends from and between the first and second supports  12 ,  14  and four attachment or mounting brackets  18 , each of which is interconnected with one of the first or second supports  12 ,  14 . 
     The towel rail  10  has a front side  20  which faces away from a wall or fixed structure  22  to which the towel rail  10  is fixed by way of the brackets  18 . The brackets  18  extend from a rear side  24  of the towel rail  10  which is opposite from the front side  20 . 
     The supports  12 ,  14 , beams  16  and brackets  18  are made from any appropriate metal such as stainless steel. 
     In this example the supports  12 ,  14  and beams  16  are circular in cross-section. 
     Each of the supports  12 ,  14  extend from an underside  26  to an upper side  28  and is sealed at its respective ends. Each support  12 ,  14  has a plurality of holes  30  formed therein. The number of holes  30  correspond with the number of beams  16  and are formed in a side of the supports  12 ,  14  between the front side  20  and the rear side  24 . The respective holes  30  in the first support  12  face towards the respective holes  30  in the second support  14 . Each hole  30  is dimensioned so that a beam  16  fits snugly therethrough. 
     The beams  16  are spaced apart in any appropriate configuration between the supports  12 ,  14  and lie one on top of the other from the underside  26  to the upper side  28 . 
     Each beam  16  extends between a first end  34  and a second, opposing end  36 . As is evident from  FIGS. 2 and 3  the first end  34  extends into the first support  12  and the second end  36  extends into the second support  14 . 
     The beam  16  has a first opening  38  formed in the first end  34  and a second opening  40  which is formed in the second end  36 . Each of the first and second openings  38 ,  40  is in the form of a slot. 
     The first opening  38  faces in a first direction  42  and the second opening  40  faces in a second direction  44  which is opposite to the first direction  42 . The direction of the first and second directions  42 ,  44  alternate between adjacent beams  16 . 
     Each of the first and second ends  34 ,  36  has a leading abutment surface  46  which abuts a respective inner surface  48  of the respective support  12 ,  14 . 
     The abutment surface  46  is complimentary in shape to the shape of the inner surface  48 . In this example the abutment surface  46  is semicircular in order for the first end  34  to lie flush against the inner surface  48 . 
     As is shown in  FIG. 3  each of the first and second ends  34 ,  36  has a recess  50  formed therein with which a fastener  52  is engageable. Each recess  50  is in the form of a hole which extends through the beam  16 . Importantly the recess  50  faces towards the rear side  24  of the towel rail  10 . 
     The fastener  52  is in the form of a grub screw which extends through an aperture  54  in the respective supports  12 ,  14 . Each aperture  54  faces towards the rear side  24 . In use the positioning of the aperture  54  hides the aperture  54  and grub screw  52  from view. 
     An elongate, flexible electrical heating element  56  is at least partially threaded through the first and second supports  12 ,  14  and the beams  16 . A cable connector  58  which is connected to the element  56  extends from the underside  26  of the first support  12  and enters the wall  22  where it is connected to electricity supply  60 . 
     In use the towel rail  10  is fixed to the wall  22  by way of the brackets  18  in a known manner and, depending on requirements electrical supply  60  is connected to the element  56 . The element  56  heats the supports  12 ,  14  and the beams  16  and the towel rail  10  acts as a radiator for the heating of a room and the drying and heating of, for example, a towel  62  which is draped over the beams  16 . 
     The towel rail  10  is manufactured by cutting appropriate lengths of supports  12 ,  14  whereafter the opposing ends of each support  12 ,  14  are plugged and sealed. The appropriately spaced holes  30  are cut in each support  12 ,  14  and the apertures  54  are formed in the supports  12 ,  14 . Appropriate lengths of beams  16  are cut whereafter the respective ends  34 ,  36  of each beam  16  is appropriately shaped to form the abutment surface  46 . The openings  38 ,  40  and the recesses  50  are also formed in the respective first and second ends  34 ,  36 . The supports  12 ,  14  and beams  16  are cut, shaped and formed by way of a laser cutter. 
     The towel rail  10  is assembled by passing the respective first and second ends  34 ,  36  of each beam  16  through opposing holes  30  in the first and second supports  12 ,  14 . The abutment surface  46  of each end  34 ,  36  is brought into abutment with each respective inner surface  48  whereafter the screw  52  is screwed through the aperture  54  and into engagement with the recess  50  in order for the screw  52  to interconnect and fix the beam  16  to the respective support  12 ,  14 . 
     The element  56  is threaded through the supports  12 ,  14  and beams  16  as they are assembled. 
     The positioning of the recesses  50  is important as this ensures that the beam  16  is fitted between the first and second supports  12 ,  14  with the opposing first and second openings  38 ,  40  facing the correct direction. As is shown in  FIG. 2  the opposing openings  38 ,  40  of adjacent beams  16  in each support  12 ,  14  face opposite directions. This is important as a course is in this manner formed through the supports  12 ,  14  and beams  16  where through the element  56  extends. 
     The brackets  18  are attached to the respective first and second supports  12 ,  14  in a known manner and fixed to the wall  22  in a known manner. 
     The connector  58  is connected to the electricity supply  60  whereafter the towel rail  10  is ready for use. 
     No welding is required to fix the beams  16  to the supports  12 ,  14  and the towel rail  10  has a neat and aesthetically pleasing finish. The apertures  54  and screws  52  face towards the rear side  24  and are not visible in use. 
     The complimentary shape between the abutment surface  46  and the inner surface  48  provides stability to the towel rail  10  and the openings  38 ,  40  allow the element  56  to pass freely though the course defined by the supports  12 ,  14  and the beams  16 . 
     As the towel rail  10  has a plurality of spaced apart beams  16  which interconnects the first and second supports  12 ,  14  a robust and stable structure is formed although only a single screw  52  is used to fix each end  34 ,  36  of each beam  16  to a respective support  12 ,  14 . 
     Although two, spaced apart and opposing supports  12 ,  14  are used in this example it is possible to use a single support  12  in the construction of the towel rail  10 . In this case each beam  16  is U-shaped and both the first and second ends  34 ,  36  of each beam  16  is fixed to the support  12  in the manner described. 
       FIG. 4  illustrates an alternative towel rail  10 A. Similar reference numerals are used for components of the towel rail  10 A which are described in respect of the towel rail  10  and only the differences between the towel rail  10 A and the towel rail  10  are described. 
     The supports  12 ,  14  and beams  16  are rectangularly shaped in cross-section. The apertures  54  in the respective supports  12 ,  14  are formed in each support  12 ,  14  at a position  70  which is off-centre on the rear side  24  of the relevant support  12 ,  14 . 
     Each of the first and second ends  34 ,  36  of each beam  16  has a stepped cut-away or shoulder  72  which faces the rear side  24 . A spacer  74  is formed on each of the first and second ends  34 ,  36  and opposes the shoulder  72 . The spacer  74  is integrally formed with the beam  16  and extends away from the respective first and second ends  34 ,  36 . Each abutment surface  46  has two spaced apart contact points  76  which abut against the inner surface  48  of the respective support  12 ,  14 . 
     The recess  50  in each end  34 ,  36  is positioned to align with the respective aperture  54  in the respective support  12 ,  14 . 
     Each hole  30  is square-shaped to accommodate the respective beam  16 . 
     In order to attach the respective ends  34 ,  36  to the respective supports  12 ,  14  each end  34 ,  36  is inserted into a hole  30  by passing the abutment surface  44  and spacer  74  through the hole  30 . The shoulder  72  allows the spacer  74  to pass through the hole  30  and when the shoulder  72  comes into contact with the respective support  12 ,  14  the end  34 ,  36  is realigned with the hole  30  in order for the end  34 ,  36  to pass through the hole  30  and for the contact points  76  to come into abutment with the inner surface  48 . The spacer  74  is brought into register with an inner corner  78  of the support  12 ,  14 . Once the screw  52  interconnects the beam  16  with the support  12 ,  14  the end  34 ,  36  is stable inside the support  12 ,  14  as the end  34 ,  36  is trapped inside the support  12 ,  14  as a result of the screw  52  and the various areas of contact between the beam  16  and support  12 ,  14  at the hole  30 , the spacer  74  and corner  78 , and the contact points  76  and the inner surface  48 . 
     The towel rail  10 A is manufactured, assembled and used in a similar manner as the towel rail  10 . 
       FIGS. 5 ,  6  and  7  show another towel rail  10 B. Similar reference numerals are used for components of the towel rail  10 B which are used and described in respect of the towel rails  10  and  10 A and only the differences between the towel rails  10  and  10 A and the towel rail  10 B are described. 
     In the towel rail  10 B the element  56  is not threaded through the supports  12 ,  14  and beams  16  in a zigzag pattern but extends through the lowermost beam  16 A and the second support  14  from where it loops into each of the remaining beams  16 . 
     This configuration assists in the assembly of the towel rail  10 B. In the towel rail  10 B the first opening  38  is omitted from each of the first ends  34  of all the beams  16  except that of the lowermost beam  16 A. 
     The second opening  40 A in each of the second ends  36  of the beams  16  is in the form of a U-shaped slot in plan which is open towards the abutment surface  46  of the second end  36  as well as into both the first direction  42  and the second direction  44 . The element  56  passes through the second opening  40 A in order to enter and exit each beam  16 . A return section  56 A of the element  56  also extends through some of the openings  40 A. 
     As is illustrated in  FIG. 7  each of the openings  40 A has a catch formation  100  which separates the opening  40 A into a mouth  102  and a channel  104  where through the element  56  extends. The catch formation  100  has a reducing taper from the mouth  102  towards the channel  104  and has opposing barbs  106  to restrict movement of the element  56  out of the channel  104 . 
     During assembly of the towel rail  10 B the element  56  is threaded through the second support  40  and appropriate lengths of the element  56  are looped through each hole  30 . Each looped section  56 B is threaded through a beam  16  with the element  56  extending from the second end  36 . The second end  36  is inserted through the hole  30  and the element  56  is pulled through the mouth  102  and past the catch formation  100  in order for it to be located in the channel  104 . The abutment surface  46  is brought into contact with the inner surface  48  and the fastener  52  is used to lock the beam  16  to the second support  14  in the manner described. The towel rail  10 B is in all other respects manufactured and used in the same manner as the towel rails  10  and  10 A. 
     The catch formation  100  prevents the element  56  from becoming tangled on the second end  36  and becoming trapped between the abutment surface  46  and the inner surface  48 . As the opening  40 A is open in both the first and second directions  42 ,  44  the element  56  can enter, exit and extend through the channel  104  in both directions. 
       FIG. 8  shows a towel rail  10 C which is an alternative version of the towel rail  10 A and which has features which are similar to those of the towel rail  10 B. Similar reference numerals are used for components of the towel rail  10 C which are used and described in respect of the towel rails  10 ,  10 A and  10 B. 
     The towel rail  10 C is constructed and used in the same manner as the towel rails  10 A,  10 B. 
       FIGS. 9 and 10  illustrate another towel rail  10 D. Similar reference numerals are used for components of the towel rail  10 D which are used and described in respect of the towel rails  10 ,  10 A,  10 B and  10 C and only the differences between the towel rail  10 D and the towel rails  10 ,  10 A,  10 B,  10 C are described. 
     In the towel rail  10 D the first and second ends  34 ,  36  of the beams  16  do not extend into the supports  12 ,  14  but is engaged with, lie on top of and abut against the supports  12 ,  14 . In the towel rail  10 D the holes  30  have a general oval shape to define a seat surface  110  against which a semicircular, outer abutment surface  46 A of the beam  16  abuts. The seat surface  110  and the abutment surface  46 A are complementary shaped and the beam  16  fits snugly against the post  12 ,  14 . 
     The recess  50  is fitted with a nut  112  and the fastener  52  is in the form of a bolt which extends through the aperture  54  and is threaded into the nut  112 . In this manner the beam  16  is drawn towards the support  12 ,  14 , is trapped in the hole  30  and is held against the support  12 ,  14 . In the towel rail  10 D the openings  38 ,  40  are in the form of holes which are in register with the respective hole  30 . The exact position and shape of each opening  38 ,  40  can vary. The element  56  is threaded through the openings  38 ,  40  in the manner described. 
     The tower rail  10 D is in other respects manufactured and used in the same manner as the towel rails  10 A,  10 B,  10 C. 
       FIGS. 11 ,  12  and  13  illustrate the connection of a bracket  18  with a support  12  of the towel rail  10 A. The bracket  18  is fixed to the support  12  by way of a connection  80 . The connection  80  has a tubular arm  82  which is attached to and extends from the bracket  18  and a flange  84  which extends away from and which is integrally formed with the support  12 . The arm  82  has a hook  86  at its leading end and a recessed catch  88  is formed in the support  12 . The hook  86  is interengaged with the catch  88  in order for the arm  82  to lie flush against the support  12 . The flange  84  extends at least partially into the arm  82  and a securing member or screw  90  passes through the arm  82  and flange  84  in order to interconnect and fix the arm  82  to the flange  84 . The arm  82  is thus interconnected with the support  12  at the hook  86  and catch  88  and at the flange  84  which opposes the hook  86  and catch  88 . 
     A passage  92  is formed from the support  12  through the connection  80  and to the bracket  18 . This allows the connector  58  to extend the support  12 , through the connection  80  and bracket  18  and into the wall  22  without being exposed to damage. 
     The connection  80  is formed by cutting the hook  86  from the arm  82  and by simultaneously cutting the flange  84  and the catch  88  in from the support  12 . The flange  84  is bent away from the support  12  in order for the flange  84  to extend at a right angle from the support  12 . Appropriate apertures  94  are formed in the arm  82  and flange  84  in order for the screw  90  to pass therethrough. 
     The connection  80  ensures that the arm  82  lies flush against the support  12  and the flange  84  and screw  90  forces the hook  86  into firm and permanent interengagement with the catch  88 . In this manner the arm  82  is fixed to the support  12  at the flange  84  and the catch  88 . 
     Importantly the flange  84 , catch  88  and passage  92  are surrounded by the arm  82  and are hidden from view. 
     The connection  80  allows the bracket  18  to be fixed to the support  12  without the need for welding and ensures a neat and aesthetically pleasing finish. Additionally the connector  58  can be hidden from view and damage. 
     The connection  80  can be used at all the brackets  18  or can alternatively be used at at least one of the brackets  18 . 
     By appropriately shaping the leading end of the arm  82  and the flange  84  the connection  80  can also be used in respect of circular supports  12 ,  14  such as those used in the towel rails  10 ,  10 B,  10 D.