Railing components and methods of making railings

Details Railing components and methods of making railings Railing components and methods of making railings

1999-04-30

2002-08-13

Browne, Lynne H. (Department: 3629)

Fences

Rail

C256S019000, C256S021000, C256SDIG005

Reexamination Certificate

active

06431526

ABSTRACT:

FIELD OF INVENTION
This invention relates to components for use in a railing system such as spindles, rails and posts.
BACKGROUND OF INVENTION
Railing systems as used to protect elevated locations and staircases, typically include upper and lower rails extending between newel posts with vertical spindles extending between the rails. These systems are assembled from individual components so that they may be custom fitted to the particular location. Some of the components are typically of non-uniform cross section and may be ornamented for aesthetic appeal.
Dimensional lumber is the most widely used material in North America for staircase components and railing systems. High value wood products such as oak, mahogany, cherry and walnut are in great demand for staircase components for their durability, warmth and richness. It takes approximately 50 years for a hardwood tree to grow in order to harvest it for this purpose and prices of these species are affected accordingly. Increasing environmental awareness is creating due concern about the depletion of these rare species of hardwoods. Pine, birch and poplar are widely used especially for the spindle component as these trees grow faster, can be harvested earlier and can be mass produced more economically due to lower wood prices. However, the variability of the wood and the grain structure make it suitable for painting rather than staining and therefore less desirable.
Metal has been used for railing components but its inherent weight has limited its use to uniform small cross sections, typically bars, that have limited aesthetic appeal. Larger and variable cross sections have not been practical from a cost and structural perspective. In some cases, cast posts have been used but their cost and weight are prohibitive.
Wrought iron is commonly used for ornamental purposes on exterior stairs, particularly in commercial environments. However the cost is prohibitive for interior residential use and the weight is considerably greater than traditional wood railings.
It is therefore an object of the present invention to obviate or mitigate the above disadvantages.
In general terms, the present invention provides a railing component comprising a tubular metal wall extending between opposite ends and having a substantially uniform wall thickness, said component varying in cross section between said opposite ends.
Preferably, a foam core is provided within the tubular metal wall and connectors are provided at opposite ends to facilitate connection.
According to a further aspect a method of manufacturing a railing component having a tubular metal body of varying cross section comprises the steps of inserting a tube into a die having an interior surface conforming to the exterior profile of said railing component, applying internal pressure to said tube to cause said tube to conform to said die and removing said tube from said die.


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