Railing components and methods of making railings

Abstract

A railing component has a tubular metal body with a non-uniform cross section. The body is formed by hydroforming and has a coating applied to the exterior. A pattern is applied to the coating to simulate a wood grain. The interior of the tubular body is filled with foam and plugs are provided at opposite ends for connection to other railing components.

1 . 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.  
     
     
         2 . A railing component according to  claim 1  wherein a foam core is provided within said tubular metal wall.  
     
     
         3 . A railing component according to  claim 1  wherein a connector is provided at at least one end.  
     
     
         4 . A railing component according to  claim 3  wherein said connector includes a wooden plug inserted within said tubular body.  
     
     
         5 . A railing component according to  claim 1  wherein an outer surface of said tubular metal wall is ornamented.  
     
     
         6 . A railing component according to  claim 5  wherein said ornamentation is embossed in said outer wall.  
     
     
         7 . A railing component according to  claim 5  wherein said ornamentation is applied to said outer wall.  
     
     
         8 . A railing component according to  claim 7  wherein said ornamentation is applied by a film encompassing said tubular metal wall.  
     
     
         9 . A railing component according to  claim 8  wherein said film is a sleeve of heat shrinkable plastics material.  
     
     
         10 . A railing component according to  claim 8  wherein said film is a vinyl polymer.  
     
     
         11 . A railing component according to  claim 1  wherein said tubular metal wall has a weld seam extending axially between said ends.  
     
     
         12 . A railing component according to  claim 11  wherein said tubular metal wall includes a plurality of interconnected planar facets and said seam is disposed in one of said facets.  
     
     
         13 . A railing component according to  claim 1  wherein said wall thickness is between 0.5 mm and 2.0 mm.  
     
     
         14 . A railing component according to  claim 13  wherein said wall thickness is 1.5 mm.  
     
     
         15 . A railing component according to  claim 13  wherein said tubular wall is contoured and has a minimal radius of not less than 2.5 mm.  
     
     
         16 . A railing component comprising a tubular metal body extending between opposite ends and varying in cross section between said ends, a core within said tubular body in engagement with at least a portion of said tubular wall, and a pair of connectors at said opposite ends.  
     
     
         17 . A railing component according to  claim 16  wherein said connectors extend partially along said body from said opposite ends.  
     
     
         18 . A railing component according to  claim 17  wherein said connectors are plugs engageable with said tubular wall and overlapping a portion thereof.  
     
     
         19 . A railing component according to  claim 18  wherein said plugs are wood.  
     
     
         20 . A railing component according to  claim 19  wherein said plugs are an interference fit in said tubular metal body.  
     
     
         21 . A railing component according to  claim 16  wherein a coating is applied to an exterior surface of said tubular body.  
     
     
         22 . A railing component according to  claim 21  wherein said coating is a plastics material.  
     
     
         23 . A railing component according to  claim 22  wherein said plastics material is a vinyl polymer.  
     
     
         24 . A railing component according to  claim 21  wherein a pattern is applied to said coating.  
     
     
         25 . A railing component according to  claim 24  wherein said pattern is embossed on said coating by application of an external force thereto.  
     
     
         26 . A railing component according to  claim 25  wherein said pattern is applied to said tubular body and said coating conforms thereto.  
     
     
         27 . A railing component according to  claim 16  wherein said tubular body has an externally contoured surface and contours on said surface have a radius of not less than twice the thickness of the tubular wall.  
     
     
         28 . A railing component according to  claim 27  wherein said tubular wall has a thickness of between 0.5 mm and 2.0 mm.  
     
     
         29 . A railing component according to  claim 28  wherein said wall thickness is 1.5 mm.  
     
     
         30 . A railing component according to  claim 27  wherein said body includes a tapered upper portion and a base having a plurality of planar facets.  
     
     
         31 . A railing component according to  claim 30  wherein said tubular wall has an axially extending weld located within one of said planar facets.  
     
     
         32 . A railing component according to  claim 30  wherein said upper tapered portion and base portion are interconnected by a contoured central portion.  
     
     
         33 . A method of manufacturing a railing component having a tubular metal body of varying cross section comprising 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.  
     
     
         34 . A method according to  claim 33  including the step of locating a foam core within said tubular body.  
     
     
         35 . A method according to  claim 34  including the step of securing connectors to opposite ends of said tubular body.  
     
     
         36 . A method according to  claim 35  wherein said connectors are inserted into said tubular body and are interference fit therewith.  
     
     
         37 . A method according to  claim 33  including the step of applying a coating to said tubular body.  
     
     
         38 . A method according to  claim 37  including the step of applying a pattern to said coating.  
     
     
         39 . A method according to  claim 37  wherein said coating is applied prior to placement in said die.  
     
     
         40 . A method according to  claim 38  wherein said pattern is applied in said die.  
     
     
         41 . A method according to  claim 38  wherein said pattern is applied after forming of said tubular body.  
     
     
         42 . A method according to  claim 38  wherein said pattern is applied to said tube during manufacture thereof.