Rack and method of forming the same
A method of forming a rack ( 45 ) (e.g. of the type used in a geared system such as a rack and pinion), suitable for use in a stairlift rail, comprises providing a plurality ( 30 ) of elongate strips ( 10 ) and securing the plurality of strips together as a stack of strips to form the rack. The strips may be profiled to provide a profile to the rack. Preferably the profile provides a toothed rack on which a gear or roller of a stairlift carriage may be driven. The rack may be formed in a continuous process. The rack may be straight or curved. A rack comprising a plurality of elongate strips secured together as a stack of strips is also described.
1. A method of forming a curved rack, the method comprising:
providing a plurality of elongate strips profiled to provide a profile to the rack;
aligning the strips to provide a stack of strips having said profile;
securing said plurality of strips together to form said rack,
wherein said securing comprises at least one process selected from the group consisting of brazing, induction brazing, copper brazing, interference brazing, seam welding, and laser welding, and
bending the rack while maintaining the positional relationship of adjacent strips.
2. The method of claim 1 , wherein the rack is suitable for use in a stairlift rail.
3. The method of claim 1 , further comprising providing a plurality of teeth.
4. A method of forming a composite rack, comprising forming a plurality of sections of rack according to claim 1 , and joining said sections of rack together to form a length of rack.
5. The method of claim 1 , wherein securing said plurality of strips together to form said rack further comprises providing features on some or all of the strips, said features being engageable with corresponding features on the strips adjacent thereto.
6. The method of claim 1 , comprising removing portions of material from each of said strips so as to reduce the mass thereof.
7. A curved rack comprising a plurality of elongate strips secured together as a stack of strips to form said rack,
wherein the strips are profiled and the strips are aligned to provide a profile to the rack,
wherein adjacent strips are joined to one another and secured together in a union of two materials by at least one process selected from the group consisting of brazing, induction brazing, copper brazing, interface brazing, seam welding, and laser welding.
8. The rack of claim 7 , wherein said rack is suitable for use in a stairlift rail.
9. The rack of claim 7 , wherein each of the profiled strips comprises a plurality of teeth.
10. The rack of claim 7 , wherein some or all of the strips comprise features that engage with each other to assist in securing them together.
11. A composite rack, comprising a plurality of sections of rack according to claim 7 , said sections of rack being joined together to form a length of rack.
12. The rack of claim 7 , wherein said rack is of a uniform thickness.