Patent Description:
The present disclosure relates generally to a method of forming a spliced joint in a handrail or other elongate article of constant cross-section.

<CIT> discloses a mould and method of forming a joint in a handrail for escalators or moving walkways. The handrail may have a generally C-shaped cross section defining an internal generally T-shaped slot. The handrail is formed by extrusion and comprises a first layer of thermoplastic material extending around the T-shaped slot. A second layer of thermoplastic material extends around the outside of the first layer and defines the exterior profile of the handrail. A slider layer lines the T-shaped slot and is bonded to the first layer. A stretch inhibitor extends within the first layer. The first layer may be formed from a harder thermoplastic than the second layer. Further known methods of joining together the ends of handrails for moving walkways are described in <CIT> and <CIT>.

According to the present invention, there is provided a method of forming a spliced joint in a moving handrail according to claim <NUM>.

Other aspects and features of the teachings disclosed herein will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific examples of the present disclosure.

The drawings included herewith are for illustrating various examples of apparatuses and methods of the present disclosure and are not intended to limit the scope of what is taught in any way. In the drawings:.

Various apparatuses or methods will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover apparatuses and methods that differ from those described below. The claimed inventions are not limited to apparatuses and methods having all of the features of any one apparatus or method described below, or to features common to multiple or all of the apparatuses or methods described below. It is possible that an apparatus or method described below is not an embodiment of any claimed invention.

In the present disclosure, various elements or components may be designated as 'first' and 'second' or alternatively as 'upper' and 'lower'. In general it will be understood that the mould assembly and other components can be used in any orientation, and references to 'upper' and 'lower' are for convenience. The mould assembly may be described for moulding a handrail in an inverted position, but it will be understood that the joint in the handrail, generally can be formed with the handrail and the components of the mould in any orientation.

Additionally, while various components of the mould assembly and handrail end portions may be identified with descriptions that indicate an orientation, such as 'lower' and 'upper', this is only to facilitate understanding, and it is not necessary that they be used or present in that orientation. In particular, a handrail has a surface that is the top surface in normal use available to be grasped, but when moulding a spliced joint, the handrail is inverted, as detailed below. In any event, in a handrail installation, the handrail is inverted in the return run.

The methods described below includes a number of separate steps, some steps, necessarily, must be carried out in a certain sequence. Other steps are not so constrained, and can be carried out in any order. The sequence described below may provide certain advantages in some circumstances, but is not limiting.

Steps of the methods will require the use of a heat paddle and a hot air gun. As they may require time to heat up, the first step can be to turn on both the heat paddle and the hot air gun, to preheat them. The hot air gun can be set to a temperature of, for example, <NUM>, depending upon the materials used for the handrail.

As shown, initial steps require preparation of the handrail ends, here designated as a first handrail end <NUM> and a second handrail end <NUM>. Corresponding parts of the first and second handrail end portions <NUM>, <NUM> are given similar and corresponding reference numerals, as 1XX and 2XX.

The handrail, as a whole, is designated by the reference numeral <NUM>. The handrail <NUM> is formed from thermoplastic body and has a generally C-shaped cross section, with an internal T-shaped slot <NUM>. The thermoplastic body of the handrail <NUM> may include a first layer of thermoplastic <NUM> and a second layer of thermoplastic <NUM>. Elongate stretch inhibitors <NUM> extend in a plane in the first layer of thermoplastic <NUM>. The stretch inhibitors <NUM> can vary in number, and may include a single stretch inhibitor element, e.g. a steel tape, and can be formed from a variety of materials. The stretch inhibitors <NUM> may be formed as steel wires, and for simplicity and brevity, may be identified as "wires" in the following description of method, but it is to be understood that any suitable stretch inhibitor can be used.

A slider fabric layer <NUM> is provided, lining the T-shaped slot <NUM> in a known manner, to provide reduced friction between the handrail <NUM> and a guide on which the handrail is mounted.

As an initial step, each of the handrail ends <NUM>, <NUM> requires horizontal cuts, to separate a scalp layer <NUM>, <NUM> from an interweave layer <NUM>, <NUM> including the stretch inhibitor <NUM>, and to separate those interweave layers <NUM>, <NUM>, from the remaining body of the handrail, in base sections indicated at <NUM>, <NUM>.

The scalp and interweave layers <NUM>, <NUM>, <NUM>, <NUM> include top sections <NUM>, <NUM> of the handrail portions. For a production splice, produced in a factory setting, the cuts may be made using a band saw. As shown in <FIG>, to cut with a band saw, the handrail is turned through <NUM>° (degrees), and the band saw then makes a cut in the vertical plane. Where a handrail splice is to be made in the field, i.e. at a site of the installation of a handrail, these cuts may be made using a knife.

With these cuts made, the first and second handrail end portions <NUM>, <NUM> can be slid onto a splicing mandrel <NUM>. The splicing mandrel <NUM> has dimensions corresponding to the internal dimensions of the T-shaped slot <NUM>, to provide a close fit for the handrail end portions <NUM>, <NUM>. The splicing mandrel <NUM> is also provided with a number of horizontal, precut grooves <NUM>, to facilitate cutting and other operations in the splice process.

As shown in <FIG>, a first step in the method is to remove the scalp layers <NUM>, <NUM>. To remove the scalp layers <NUM>, <NUM>, a metal square can be used as a straight edge and a utility knife can be used to cut through the thermoplastic, taking care not to cut or score the stretch inhibitor <NUM>.

Both handrail end portions <NUM>, <NUM> are marked at <NUM>° across the end of the interweave layers <NUM>, <NUM> at <NUM> from the end of the interweave layers <NUM>, <NUM>. Wire cutters are then used to cut across this line, and to discard the <NUM> pieces of the interweave layers <NUM>, <NUM>, as shown at <NUM> in <FIG>.

The interweave layers <NUM>, <NUM> will need to be cut, to form a desired interweave pattern. <FIG>, described below, shows an exemplary interweave pattern for handrails with twenty wires <NUM> and fourteen wires <NUM>. As shown in <FIG>, an interweave pattern for twenty wires has a female end pattern <NUM> and a male end pattern <NUM>. As shown, the wires or stretch inhibitors <NUM> are cut to lengths of <NUM>, <NUM>, <NUM>, <NUM> and <NUM>, from an end of the interweave pattern indicated at <NUM>. For a handrail with fourteen wires or stretch inhibitors <NUM>, there may be four different lengths, measured as <NUM>, <NUM>, <NUM> and <NUM>, from the end of the interweave pattern.

As shown in <FIG>, each interweave pattern is formed by vertical cuts made with a knife along the length of the interweave layers <NUM>, <NUM>. With these longitudinal cuts made, wire cutters are used to cut off the portions of the wires <NUM> and the corresponding surrounding thermoplastic, to leave the patterns shown in <FIG>. As detailed below, the slider fabric layer <NUM>, in one of the handrail ends <NUM>, <NUM> is formed with a tab <NUM>. It may also have the female interweave pattern <NUM>.

With the handrail ends <NUM>, <NUM> mounted on the mandrel <NUM>, the interweave layers <NUM>, <NUM> are folded back, and may be held with hand clamps, to leave the remaining base sections <NUM>, <NUM> exposed.

As shown in <FIG>, on a top surface <NUM>, <NUM> of the base section <NUM>, <NUM>, a <NUM> degree centerline <NUM> is drawn, generally across the top of the slider fabric layer <NUM> and a covering layer of polyurethane. For the interweave pattern for twenty wires the line <NUM> will be drawn at <NUM> from the end of the respective first and second handrail end.

The cut forming the remaining body portions or base sections <NUM>, <NUM>, results in each of the body portions <NUM>, <NUM> having shoulder portions <NUM>, <NUM> connected by a thin central portion <NUM>, <NUM>. The central portions <NUM>, <NUM> include a thin layer of thermoplastic above a forward part of the slider layer <NUM>.

As shown in <FIG>, from the centerline <NUM>, <NUM>, score lines <NUM>, <NUM> are made along the length of the handrail, approximately where the slider fabric <NUM> turns down around the splicing mandrel <NUM>. In cutting these lines <NUM>, <NUM>, care is to be taken to not cut through the slider fabric <NUM>, and these lines <NUM>, <NUM> serve to separate the thermoplastic of the shoulder portions <NUM>, <NUM> from the central portions <NUM>, <NUM>, with the slider layer <NUM> being intact.

Then, using either a pair of small device vise grips, or a pair of ply grippers, each of the shoulder portions <NUM>, <NUM> is grasped and pulled away from the underlining slider fabric <NUM> at the shoulder below the cuts or score lines <NUM>, <NUM>, as shown in <FIG>.

As shown in <FIG>, edges <NUM> of the slider fabric <NUM> are embedded in the polyurethane of the second thermoplastic layer <NUM>, and the previous step is not intended to remove edges of the slider fabric layer <NUM> from the polyurethane.

Once the polyurethane of the shoulder portions <NUM>, <NUM> has been detached as detailed above, from approximately <NUM> from the cut end of the respective handrail end portion <NUM>, <NUM>, the handrail end portion <NUM>, <NUM> is removed from the mandrel <NUM>, turned over, and clamped onto the mandrel <NUM> in an inverted position, as shown in <FIG>.

The centerline <NUM>, <NUM> is then manually transferred around shoulders of the handrail to the top of the shoulder portions <NUM>, <NUM>, and into the belly of the handrail, so as to be marked on the interior of the slider fabric <NUM> as indicated at <NUM>.

As shown in <FIG> for the handrail end portion <NUM> and a similar procedure is applied to the other handrail end portion <NUM>, a mark <NUM> is provided on the shoulder portion <NUM>, <NUM> inside the lip, on the centerline <NUM>. From this mark <NUM>, a required distance, for example <NUM> or <NUM>, is measured back from the centerline <NUM>, and a mark <NUM> is made at the top of the lip. The marks <NUM> and <NUM> are then joined with a straight line <NUM> straight in the sense that it lies in a plane at a <NUM>° angle to a plane perpendicular to the axis of the handrail at the centerline <NUM>, but appears curved in the drawings, and this is done for both sides of the shoulder portions <NUM>.

Using, for example, a Dremel™, a rotary abrasive tool, or other tool to grind or otherwise remove a line portion of the slider fabric layer <NUM>, a line is traced along the straight lines <NUM>.

With a utility knife, lengthwise cuts are made along the edge of the shoulder portions <NUM> as shown in <FIG> and <FIG>, and indicated at <NUM>. These cuts are from the centerline <NUM>, minus the <NUM>, to the cut end of the handrail, for both sides of the handrail portion end <NUM>. The knife can be inclined vertically and it should be ensured that it catches the edge of the slider fabric layer <NUM> buried in the polyurethane or thermoplastic.

Starting from the cut end of the handrail, a pair of small vise grips is used to remove the fabric from the throat area, i.e. the inside of the T-shaped slot, and around the lip area. This may require leveraging motion and the fabric layer <NUM> is removed back up to the centerline <NUM>, including the area that is previously cut back <NUM> from the centerline.

Using a Dremel™ or other suitable tool (e.g. a Dremel™ bit No. <NUM>), the remaining fabric of the slider fabric layer <NUM> is removed along the shoulder portions <NUM>. The tool <NUM> should be positioned as shown in <FIG>, to remove only the fabric along the line, without cutting too deeply into the thermoplastic carcass. All fabric should be removed from this area to prevent possible failure of the splice in use.

The first handrail end portion <NUM> is then returned to the normal upright position and slipped back onto the splicing mandrel <NUM>. A fabric end portion <NUM>, between the centerline <NUM> and the end surface of the first handrail end portion <NUM> is then entirely free of the shoulder portions <NUM>. As shown in <FIG>, two parallel lines <NUM> are drawn from the corner which was cut with the Dremel™ tool towards the end of the splice, using a utility knife. Measuring <NUM> from the centerline <NUM>, a cut is made at <NUM>° towards the end of the splice. A metal carpenter's square, or the like, is used to cut across this line to form an angled tab <NUM>.

For other handrails, a measurement is made <NUM> from the centerline <NUM> towards the end of the first handrail <NUM> with the fabric layer at <NUM> degrees. A cut is made across this line to form a rectangular tab at <NUM>.

For the second, or other handrail, end <NUM>, the fabric <NUM> is cut across at the centerline <NUM>, using a metal carpenter's square at <NUM> degrees.

The tab <NUM> size should be a minimum of <NUM> x <NUM>. The remaining fabric can be discarded.

The shoulder portions <NUM> are removed at the centerline <NUM> with a utility knife. Isopropyl or ethyl alcohol can be used on the blade during cutting to provide lubrication. A clamp may be used to hold the shoulders portions <NUM> against the mandrel <NUM>, to help keep the cuts straight. A sawing action may be used to avoid deforming the handrail, thereby creating an uneven cut. To ensure a good weld, as detailed below, a square cut should be achieved.

Once the shoulder portions <NUM> have been cut, it should be ensured that the cut to the bottom of the lip is as perpendicular to the access of the handrail as possible, so that a good weld can be achieved later.

For any cuts through the shoulder portions <NUM> that are poorly made, the cut surface should be moved to a center slot <NUM> of the mandrel <NUM>, the shoulders should then be cut square using a utility knife in a sawing motion, while following the edge of the center slot <NUM>. While performing the cut, the shoulder portions <NUM> should be held firm against the mandrel <NUM>, so that a utility knife follows the flat surface of the center slot <NUM>. Again, isopropyl alcohol can be used as a lubricant.

To assemble a splice, both of the handrail end portions <NUM>, <NUM> are slid onto the splice mandrel <NUM>, so that the ends of the slider fabric layers line up with edges of the center slot <NUM>. The tab <NUM> is tucked under the first handrail end portions <NUM>, to ensure that it will not interfere or get damaged in the next step.

A gap is provided between the handrail end portions <NUM>, <NUM> to allow enough space for a heat paddle <NUM> to be placed between the two handrail ends, as shown in <FIG>.

The heat paddle <NUM> is heated to a desired temperature, and if required, it can be cleaned using a wire brush. The heat paddle <NUM> is placed between the end portions <NUM>, <NUM>, making sure that the <NUM> overlap does not get damaged, and inserted into the slot <NUM>. The end portions <NUM>, <NUM> are pushed against the heat paddle <NUM>. Once the end surfaces of the first and second handrail end portions <NUM>, <NUM> start melting and flaring out, to the extent to providing <NUM> mushroom effect, the heat paddle <NUM> is removed, as shown in <FIG>, and the handrail ends <NUM>, <NUM> are quickly pushed tightly together for <NUM> to <NUM> seconds, to bond the ends together.

The following elements may be considered, to ensure a good bond: (a) the melt is even all the way around; (b) the ends are pushed together very quickly; (c) the shoulders are properly aligned with each other during the welding, while pushing the two ends together; and (d) once the two handrail end portions <NUM>, <NUM> are welded together, the resulted joint is inspected by flexing the joint by hand and visually checking for cracks; if the joint cracks, the splice must be separated, re-welded and tested again.

Referring to <FIG>, with the interweave layers <NUM>, <NUM> held back, body ply layers <NUM>, <NUM> can be inserted to compensate for the thermoplastic lost due to a cutting step.

On the second top surface <NUM>, above where the tab <NUM> will be, a line is marked <NUM> from the centerline <NUM>. A body ply <NUM> is provided and inserted under the interweave layer <NUM>. It is cut across at the line <NUM>. When an angled tab is provided, it is then further cut at an angle of <NUM>° at <NUM>, so that this body ply <NUM> has a shape corresponding to the underlining tab and not extending over the tab <NUM>.

Correspondingly, for the first handrail end <NUM>, a body ply <NUM> is provided, which again is fitted straight under the interweave layer <NUM>. It is cut so that it extents up to the centerline <NUM>.

The body ply layers <NUM>, <NUM> are welded to the underlying body portions <NUM>, <NUM> of the handrail, by a heat gun. The heat gun may be set to a temperature of <NUM>. The heat gun may be aimed between the respective ply and the underlining thermoplastic, to warm the thermoplastic before rolling it down, for example with a roller, e.g. a <NUM> inch roller. When rolling, care may be taken to ensure all air is expelled, as trapped air can result in voids in the spliced joint. It may only be necessary to tack the body ply layers <NUM>, <NUM> in place without a complete weld being performed at this time.

A utility knife can be used to trim the mushroom effect from the shoulder portions <NUM>, <NUM>.

The interweave layers <NUM>, <NUM> can then be released by removing the hand clamps. If not already done so, the interweave patterns of <FIG> can then be formed or made.

The interweave pattern may be formed at this time, by first forming the male end pattern <NUM>. Using the male end pattern <NUM> as a template, the female end pattern <NUM> can then be cut. The end portions of the interweave butt together with a <NUM> gap, with no overlap.

As required, third and fourth plies of thermoplastic can be provided above the interweave, the plies can vary by style and can vary in dimension (thickness). There is usually a third ply and sometimes a fourth.

If required, a heat gun and a roller can be used to ensure that the end patterns in the two interweave layers <NUM>, <NUM> are at least tacked down onto the underlining thermoplastic.

A hot air gun is used to warm the underside of a first leg of the female end of the interweave layer <NUM> that is to be welded down or tacked in place. A similar procedure is used for the second leg of the female end to weld or tack it in place, and in both cases, expel air. Similar procedures are followed for the male end of the interweave.

To complete the splice joint, a cap <NUM> is prepared, as shown in <FIG>. The cap <NUM> is prepared by cutting a piece from a length of the handrail corresponding to the removed scalp layers <NUM>, <NUM>. As such, the cap <NUM> should have the thickness of the scalp <NUM>, <NUM> plus the thickness of any material removed by the band saw or other cutting tool, minus allowance for any material effectively replaced by insertion of plies, as detailed above.

The splice as assembled leaves space between vertical end edges <NUM>, <NUM> of the handrail ends <NUM>, <NUM>. The cap <NUM> is cut to be slightly longer than this distance.

To mount the cap <NUM>, one end of the cap <NUM> is positioned over the splice area with an end of the cap <NUM> facing and spaced by few mm from an end of edge surface <NUM>, <NUM>. A hot air gun is used to heat the end surface of the cap <NUM> and the facing edge surface. When sufficiently heated, the end surface is pressed up against the hot edge surface; the heating may be such as not to cause melting of the material. The cap should be level and with no cracks where air can be trapped.

At the other end of the splice, the cap should be checked to ensure that it is straight and centered in the splice area. Using a metal carbon square guide and utility knife, the cap <NUM> is then trimmed so that it is slightly longer than the space between the two facing edge surfaces <NUM>, <NUM>, e.g. the cap <NUM> can extend <NUM> past, by overlapping the other edge surface. The cap may then bulge upwards.

As for the other end, a hot air gun is used to heat the end surfaces of the cap <NUM> and the other more facing edge surface of the other handrail end. The cap is then pressed tightly against the edge surface. Again, this may be done so as not to overheat the cap and so as not to cause melting material, but to leave the cap level with no trapped air.

Finally, the spliced area is cleaned and a protective film is provided to the splice. The protective film is to keep the surface clean and protected until installation. It will be removed prior to installation. It is a clear plastic film that is applied to the entire handrail during extrusion. During splicing the film is removed and a new section is added once the splice is complete.

The spliced joint is then inverted and the handrail can be clamped in an inverted position with the belly interior of the handrail facing upwards, as shown in <FIG>.

A piece of adhesive ply is then inserted. The adhesive TPU ply differs in composition to the body plies, and is very thin (<NUM>). It includes a layer of slider fabric with a thin layer of TPU adhesive, and the same material is used to form saddles, as detailed below. The adhesive TPU ply is cut to be approximately <NUM>-<NUM> longer and <NUM> to <NUM> wider than the tab <NUM> and is placed under the tab <NUM>.

Using a hot air gun with a lower blowing speed, the adhesive ply is heated underneath the tab <NUM>, and the tab <NUM> is then pushed into the belly of the handrail to have it adhere to the slider fabric <NUM>. The adhesive extending beyond the tab is then rolled back to the edge of the tab forming a bead that fills the step between tab and belly.

With the tab <NUM> adhered to the slider fabric <NUM> of the handrail end portions, any mushroom effect created by the bonding of the first and second handrail ends <NUM>, <NUM>, can be trimmed and removed from the top of the lip to the slider in the belly inside the throat area using a rotary tool. This material is removed to ensure that the splice is not too bulky and will fit into a mould correctly.

The cavity formed in the handrail lip where the slider edges has been removed <NUM> is filled with strips of handrail cover material and bonded using a hot air gun.

Fresh, unused slider fabric, including an adhesive layer, is then obtained and cut to form saddles <NUM>. This saddle material is pre coated with a TPU adhesive, and is the same material as the ply used to secure the tab in position, as mentioned above. <FIG> shows the shape of a saddle, and a saddle template is provided for cutting the saddle and having the same shape as the saddle <NUM> shown in <FIG>. The saddle template is aligned on the saddle material at <NUM>°, using a carpenter's square or the like. The bias is <NUM> degrees from the longitudinal direction, i.e. <NUM> degrees to the lines <NUM>, <NUM>. The saddle <NUM> is cut from the fabric material to the shape of the template. As shown in <FIG>, a mark <NUM> is made on the shoulder of handrail <NUM> from the face of the lip, as indicated by arrows, to align an edge of the saddle.

The saddle <NUM> can be considered a trapezoid, with end triangles cut off. Thus, the saddle <NUM> has, relative to its position in the handrail, an inner edge <NUM> and an outer edge <NUM> parallel to one another, and two end edges <NUM> perpendicular to those inner and outer edges <NUM>, <NUM>, respectively. Two inclined edges <NUM> complete the shape of the saddle <NUM>.

The saddle <NUM> is then placed on the shoulder portions <NUM>, centered on the weld joint, with the saddle outer edge <NUM> aligned with the <NUM> mark made above. The saddle is held and heat is applied to the shoulder portions <NUM> and the adhesive of the saddle. The saddle <NUM> is pressed down onto the shoulders so that it is centered on the weld and is aligned with the <NUM> mark. The material should be heated sufficiently to give a proper bond. A hot air gun may be used to heat the fabric side of the saddle and to continue to fold the saddle over the top lip facing and into the throat area. All edges should be as straight and as parallel as possible. The adhesive should not be overheated as it may not be desirable to have the saddle bond completely with a slider fabric. At this time, the main function of heating is to make the saddle <NUM> more flexible.

The above steps are repeated for a saddle <NUM> on the other side of the splice joint.

After the saddle <NUM> has been tucked into the belly of the handrail, heat is applied to the edges of the saddles <NUM> that proceeds over the lip face and pressed firmly to ensure that the saddle is properly positioned when the splice is placed in the mould.

With both saddles <NUM> in place, a piece of handrail that was used to make the cap <NUM> can then be used to obtain strips <NUM> of cover material to seal the edges of the saddles <NUM>. For this purpose, this piece of the handrail is turned upside down.

The strips <NUM> of cover material can be obtained, by taking a piece of the handrail, and marking three or four spots along the length of the handrail shoulder. These may be measured and marked, using a grease pencil or other removable marking device, <NUM> and <NUM> around the shoulder from where the cover material falls on top of the lip. A utility knife may then be used to remove a strip <NUM> of covering material from the shoulder, using the marks above to determine edges to this strip <NUM>. The strip of materials may be <NUM> or less in thickness.

These strips <NUM> are cut to a length of <NUM>, for example. As shown in <FIG>, each of these pieces is centered on a saddle. For some handrails, the length of the cover piece should be about <NUM> beyond the saddle edge.

A hot air gun (and this may be with a maximum temperature not exceeding <NUM>) is used to tack the piece of covering material to either side of one of the saddles <NUM>, making sure that the width of the piece, for example, <NUM>, is centered over the edge of the saddle <NUM>. The hot air gun may be used to heat and stick down the saddle edge of the cover piece first, before heating and sticking down the shoulder edge of the piece. It may be found that it is more difficult to tack down the piece on the saddle sides, and if so, it may be preferable to start with the heating, such that only the cover pieces are melted, and not the material of the saddle <NUM>. Melting of the saddle material may cause the splice to fail prematurely.

One of the functions of the cover piece is to help seal the saddle adhesive and prevent it from falling out.

To mould the finish splice, an appropriate mould with a core element is selected, for example, as disclosed in <CIT> and the corresponding International Application entitled MOULD ASSEMBLY FOR FORMING A SPLICED JOINT IN A HANDRAIL OR OTHER ELONGATE ARTICLE. The core is inserted into the T-shape slot <NUM> at the splice. If the core appears to stick, while removing from the splice or if adhesive is being removed from the belly of the handrail, leaving a gap at the end of the slider tap, a moulding release agent can be applied to the core where the slider tab and the saddle are located.

Before inserting the core into the handrail, the shoulders and saddles can be gently heated with a heat gun to make them more pliable, to help the handrail fit tightly around the core.

The core can be inserted by centering over the splice area and using a putty knife to pry the core into the front shoulder, insertion of the core should be done so as not to move any of the saddles during the insertion process.

Claim 1:
A method of forming a spliced joint in a moving handrail (<NUM>), the handrail (<NUM>), comprising:
a thermoplastic body having a C-shaped cross section and defining a T-shaped slot (<NUM>);
a stretch inhibitor (<NUM>) in the thermoplastic body, the stretch inhibitor (<NUM>) is arranged above the T-shaped slot (<NUM>), when the handrail (<NUM>) is in an upright position; and
a slider fabric layer (<NUM>) lining the T-shaped slot (<NUM>),
wherein the handrail (<NUM>) comprises first and second end portion (<NUM>, <NUM>), each comprising a forward part extending from an end surface of the end portion and a rear part adjacent the forward part, the method comprising:
in each of the rear and forward parts of the first and second end portions (<NUM>, <NUM>), providing a first cut, which extends horizontally when the handrail (<NUM>) is in the upright position, to separate a top section (<NUM>, <NUM>) of the thermoplastic body from a base section (<NUM>, <NUM>), wherein the base section (<NUM>, <NUM>) comprises shoulder portions (<NUM>, <NUM>) of the thermoplastic body, the slider fabric layer (<NUM>), and a layer of thermoplastic above the slider fabric layer (<NUM>) joining the shoulder portions (<NUM>, <NUM>) together;
for each end portion, removing at least the shoulder portions (<NUM>, <NUM>) from the forward part thereof, to leave a central portion (<NUM>, <NUM>) comprising a forward part of the slider fabric layer (<NUM>) and the layer of thermoplastic;
cutting the forward parts of the slider fabric layer (<NUM>) and the layer of thermoplastic to form a tab portion (<NUM>, <NUM>); and
assembling the first and second end portions (<NUM>, <NUM>) together to form a spliced joint for moulding.