U.S. patent application number 10/199380 was filed with the patent office on 2003-05-08 for modular railing and bracket therefor.
Invention is credited to Gardner, Arthur A..
Application Number | 20030085395 10/199380 |
Document ID | / |
Family ID | 26894707 |
Filed Date | 2003-05-08 |
United States Patent
Application |
20030085395 |
Kind Code |
A1 |
Gardner, Arthur A. |
May 8, 2003 |
Modular railing and bracket therefor
Abstract
A modular railing including a plurality of upright posts and a
plurality of hand rails extending between adjacent ones of the
upright posts is described. The handrails each include a plastic
outer shell. A plurality of lower rails extend between the adjacent
ones of the upright posts. At least one of the handrails or lower
rails is positioned at an oblique angle relative to the post. A
plurality of spindles extend between the handrails and the lower
rails. At least one bowed connector couples the at least one
obliquely oriented rail to at least one upright post. The bowed
connector includes a bracketed end for mounting to a post and an
angled end for receiving an end portion of the at least one
obliquely oriented rail.
Inventors: |
Gardner, Arthur A.;
(Marietta, GA) |
Correspondence
Address: |
GARDNER GROFF, P.C.
PAPER MILL VILLAGE, BUILDING 23
600 VILLAGE TRACE
SUITE 300
MARIETTA
GA
30067
US
|
Family ID: |
26894707 |
Appl. No.: |
10/199380 |
Filed: |
July 19, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60332794 |
Nov 6, 2001 |
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Current U.S.
Class: |
256/65.02 |
Current CPC
Class: |
E04F 2011/1821 20130101;
E04F 2011/1889 20130101; E04F 2011/1897 20130101; E04F 11/1817
20130101; E04F 2011/1819 20130101; E04F 11/1834 20130101 |
Class at
Publication: |
256/65.02 |
International
Class: |
E04H 017/14; E04H
017/22; E04H 017/24 |
Claims
What is claimed is:
1. A modular railing comprising: a plurality of upright posts; a
plurality of handrails extending between adjacent ones of the
upright posts; a plurality of lower rails extending between the
adjacent ones of the upright posts, wherein at least one of the
handrails or lower rails is positioned at an oblique angle relative
to the post; a plurality of spindles extending between the
handrails and the lower rails; at least one bowed connector
coupling the at least one obliquely oriented rail to at least one
upright post, wherein the bowed connector has a bracketed end for
mounting to a post and an angled end for receiving an end portion
of the at least one obliquely oriented rail.
2. A modular railing as claimed in claim 1 wherein the angled end
of the bowed connector has a non-rectangular shaped opening
matching a cross-sectional profile of the handrails to allow the
bowed connector to be slipped over end portions of the
handrails.
3. A modular railing as claimed in claim 1 wherein the angled end
of the bowed connector is oriented at an oblique angle relative to
the bracketed end of the bowed connector.
4. A modular railing as claimed in claim 1 wherein the handrails,
lower rails, and bowed connector have a weather resistant exterior
surface.
5. A modular railing as claimed in claim 1 wherein the bracketed
end of the bowed connector includes flanges to allow the brackets
to be fastened to the upright posts with fasteners.
6. In a modular railing of the type having a plurality of posts, a
plurality of rails extending between adjacent ones of the upright
posts, wherein at least one of the rails is positioned at an
oblique angle relative to an adjacent post, the improvement therein
comprising: at least one bowed connector coupling the obliquely
oriented rail to at least one post, wherein the bowed connector has
a bracketed end and an angled end for receiving an end portion of
the at least one obliquely oriented rail therein.
7. The improvement as claimed in claim 6 wherein the angled end of
the bowed connector has a shaped opening matching a cross-sectional
profile of the rails to allow the bowed connector to be slipped
over end portions of the rails.
8. The improvement of claim 7 wherein the bowed connector includes
a first portion and a second portion oriented at an oblique angle
relative to said first portion.
9. The improvement of claim 8 wherein the bowed connector is made
of a weatherable plastic.
10. The improvement of claim 6 wherein the bowed connector
comprises an outer surface made of weatherable PVC.
11. A plastic mounting bracket for securing a railing to an upright
post, said plastic mounting bracket comprising: a first portion
adapted to be secured to the upright post; and a second portion
extending from the first portion at an oblique angle thereto, said
second portion including a shaped opening for receiving an end of
the railing therein.
12. The plastic mounting bracket as claimed in claim 11 wherein at
least an exterior surface of said plastic mounting bracket
comprises a weatherable PVC.
13. The plastic mounting bracket as claimed in claim 11 wherein
said first portion includes a mounting flange for mounting to the
upright post.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to railing, and more
particularly, to indoor and outdoor railing used with steps.
BACKGROUND OF THE INVENTION
[0002] Outdoor decks are extremely popular in residential home
construction. Homes and apartments, as well as a variety of other
buildings, often incorporate exterior decks into their design.
Additionally, decks are commonly added onto existing structures and
landscapes. These decks provide convenient spaces for a variety of
outdoor activities, including cookouts, dining and sunbathing, as
well as other leisure activities. Moreover, decks typically are
provided with a railing or perimeter fence to keep people from
falling over the edge of the deck.
[0003] Wood products traditionally have been the primary source of
materials for use in decking construction. However, wood products
are becoming increasingly scarce due to the harvesting of trees at
ever faster rates and the rather limited rate at which timber
resources can be replenished. Also, environmental concerns and
regulations directed to conservation or preservation of forests
tend to restrict the availability of wood products. With the
diminishing availability of timber resources, wood products are
becoming increasingly expensive. There is, therefore, a substantial
need for long-lasting substitute construction materials that can
reduce harvesting of timber. One potential approach to addressing
the above need is to provide substitute decking products made of
plastic, rather than wood. However, because deck products must be
capable of sustaining certain loads, replacement products need to
be stable and rigid. The material should also be capable of
economical manufacture and be relatively inexpensive. It also needs
to be easily installed and used in the field.
[0004] A variety of plastic building products are known. For
example, U.S. Pat. No. 4,045,603 describes a three-layer synthetic
construction material made from recycled waste thermoplastic
synthetic resin material and cellulose fiber aggregate. This
material includes face surfaces consisting essentially of
re-hardened fused and rolled thermoplastic synthetic resin material
bits, and an intervening core material consisting essentially of a
compressed non-homogenous mixture of cellulose aggregate material
bits and re-hardened fused thermoplastic synthetic resin material
bits. U.S. Pat. No. 3,764,245 describes an apparatus for producing
a light structural board of thermoplastic resin.
[0005] U.S. Pat. No. 5,253,458 describes a simulated log made from
a cast polyvinlychloride (PVC) pipe, selectively filled with a hard
cast foam or bead type foam. This patent further describes that the
cast PVC pipe is first manufactured and then subsequently filled
with the foam filler.
[0006] U.S. Pat. No. 5,617,697 of Erwin describes a composite deck
post for use with a wood joist of wood deck which includes an
elongate, hollow, extruded plastic shell in which an elongate
tubular metal stiffening member is positioned there within and is
rigidly secured thereto using a metal fastener that extends through
the plastic shell and the stiffening member.
[0007] U.S. Pat. No. 5,626,331 of Erwin describes a composite
spindle for use in a fence or deck railing and comprises a plastic
outer shell having a first end section, a second end section
opposite the first end section, and a middle section. An elongate
metal reinforcing element is positioned within the outer shell and
extends from the first end section to the second end section. A
rigid plastic foam is placed within at least a portion of the first
and second end sections and substantially surrounds portions of the
metal reinforcing element. Moreover, it is known in the art to
construct railings out of plastic. For example, U.S. Pat. No.
4,477,058 of Lowery discloses a fence comprising plastic vertical
posts, plastic horizontal rails interconnected to the posts by pins
which pass through holes formed in the posts and in the ends of the
horizontal rails, and plastic vertical fence boards having holes
formed therein for receiving pegs extending from the horizontal
rails for snapping the fence boards onto the horizontal rails.
[0008] U.S. Pat. No 4,809,955 of Veilleux discloses a plastic fence
or railing assembly comprising extruded plastic posts having
U-shaped open-ended channels formed therein which function as guide
slots for receiving the ends of horizontal rails inserted into the
channels and held in a desired spatial relationship by separator
elements.
[0009] U.S. Pat No 5,161,783 of German relates to a fence rail
construction comprising hollow tubular PVC posts having openings
formed therein for receiving a hollow tubular PVC rail. Prior to
inserting the rail into the openings formed in the posts, a hollow
tubular PVC sleeve having flanges is inserted within the posts in
alignment with the openings formed in the posts. The ends of the
rails are then inserted into the openings and the sleeves to form a
rigid connection between the rails and the posts. In order to
assemble the fence, openings are cut in the posts at the required
heights. Adhesive is then applied to the sleeves which is then
inserted into the hollow openings formed in the top of the posts,
such that the sleeves are aligned with the openings formed in the
posts. Adhesive is then applied to the ends of the horizontal rails
which are then inserted into the openings formed in the posts and
into the sleeves.
[0010] U.S. Pat. No 6,017,019 of Erwin relates to a modular railing
that includes a plurality of upright posts and a plurality of
composite handrails extending between adjacent ones of the upright
posts. Each of the composite handrails has a plastic shell and an
internal metal reinforcing element that extends longitudinally
inside the plastic shell of the handrails. A plurality of lower
rails extend between adjacent posts. A plurality of brackets couple
the handrails and the lower rails with the upright posts. The
brackets are adapted to be slipped over end portions of the
handrails and lower rails and are adapted to be fixed to the
upright posts. At least some of the brackets have a nonrectangular
shaped opening matching a cross-sectional profile of the handrails
to allow the brackets to be slipped over end portions of the
handrails. At least one of the handrails is oriented at an oblique
angle relative to one of the upright posts. At least one of the
brackets has an elongated non-rectangular shaped opening to receive
the obliquely oriented handrail.
[0011] The plastic fencing or railing of the types just described
represent a laudatory improvement over earlier wood products in
many respects. But they leave room for improvement in the area of
connecting railings to posts at oblique angles.
[0012] Accordingly, it can be seen that there is a need yet in the
art for plastic railing which provides a strong finished product at
minimal cost, is weather-resistant, and adapts easily when
connecting railings to posts at oblique angles, such as with
stairs. It is to the provision of such a railing and a bracket
therefor that the present invention is primarily directed.
SUMMARY OF THE INVENTION
[0013] Briefly described, the present invention comprises a modular
railing including a plurality of upright posts and a plurality of
handrails extending between adjacent ones of the upright posts. A
plurality of lower rails extend between the adjacent ones of the
upright posts. At least one of the handrails or lower rails is
positioned at an oblique angle relative to one of the posts. A
plurality of spindles extend between the handrails and the lower
rails. At least one bowed connector couples the at least one
obliquely oriented rail to at least one upright post. The bowed
connector includes a flanged end for mounting to a post.
[0014] In another form, the invention comprises a modular railing
of the type having a plurality of posts, a plurality of rails
extending between adjacent ones of the upright posts, wherein at
least one of the rails is positioned at an oblique angle relative
to an adjacent post. The improvement therein comprises at least one
bowed connector coupling the obliquely oriented rail to at least
one post. The bowed connector has a flanged end for mounting to a
post and an elongated end for receiving an end portion of the at
least one obliquely oriented rail therein.
[0015] In another form, the invention comprises a plastic mounting
bracket for securing a railing to an upright post at an oblique
angle thereto. The mounting bracket includes a first portion
adapted to be secured to the upright post. A second portion extends
from the first portion at an oblique angle thereto and the second
portion includes a shaped opening for receiving an end of the
railing therein.
[0016] With this construction, the resulting structure is easily
manufactured and installed, is very strong and sturdy, is quite
weatherable, and effectively connects angled rails. The modular
railing is very easy to manufacture, provides excellent appearance,
and provides good strength (both in terms of bending resistance and
compression load-carrying capability).
[0017] These and other advantages, and features of the present
invention will become more apparent upon reading the following
specification in conjunction with the accompanying drawing
figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0018] FIG. 1 is a perspective, partially exploded view of a
portion of the modular composite railing according to a preferred
form of the invention.
[0019] FIG. 2 is a front view of a bracket portion of the modular
composite railing of FIG. 1.
[0020] FIG. 3 is a perspective illustration of a portion of the
modular composite railing of FIG. 1, showing the bracket portion of
FIG. 2 shrouding an end of a handrail portion.
[0021] FIG. 4A is a partial side view of another portion of the
modular railing of FIG. 1 for use with steps illustrating bowed
connectors that couple angled rails with an upright post.
[0022] FIG. 4B is a cross-sectional view of the bowed connector of
FIG. 4A viewed along lines 4B-4B of FIG. 4A.
[0023] FIG. 5 is an enlarged side view of the bowed connector of
FIG. 4A illustrating the position of a railing within the bowed
connector.
[0024] FIG. 6 is an alternate construction of the bowed connector
of FIG. 5.
[0025] FIG. 7 is another alternate construction of the bowed
connector of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Referring now in detail to the drawing figures, wherein like
reference numerals represent like parts throughout the several
views, FIG. 1 shows a modular railing 10 according to a preferred
form of the invention. The modular railing is in the form of an
assembly of individual components which are manufactured as
separate components and then can be assembled in the field by an
installer or a do-it-yourselfer. The modular railing assembly 10
includes a number of upright posts, such as post 11 and post 12.
Extending between adjacent ones of the posts are upper rails or
handrails, such as handrails 13, 14, and 15. Also extending between
the adjacent ones of the upright posts are lower rails, such as
lower rails 16, 17, and 18. It is to be understood that the
individual components can be made of a single plastic material, can
be formed from different plastics, or can be a composite of plastic
and non-plastic elements (even some metal components can be
employed).
[0027] Extending between the handrails 13-15 and the lower rails
16-18 preferably are a plurality of spindles, such as spindles
21-27. The spindles are fitted into holes formed in the lower
rails, such as holes 32-36 for spindles 22-26 and unshown holes
formed in the underside of the handrails. Preferably, the spindles
are made in accordance with U.S. Pat. No. 5,626,331 of Erwin by
which each spindle includes a plastic outer shell having a first
end, a second end, and a middle section. An elongate metal
reinforcing element is positioned within the outer shell and
extends from the first end to the second end. A rigid plastic foam
is placed within at least a portion of the end sections and
substantially surrounds portions of the metal reinforcing
element.
[0028] As shown in FIG. 1, the handrails preferably have an
attractive, contoured profile or shape, while the lower rails are
simple rectangular elements. It will be appreciated by those
skilled in the art that the profiles of the handrails and the lower
rails can be modified as desired. Moreover, as shown in the
figures, the handrails can be composite units having a plastic
outer shell and a metal reinforcing element placed therewithin.
This will be described in more detail in connection with FIG. 3.
Similarly, the lower rails 16-18 could be reinforced, if
desired.
[0029] The upright posts, such as posts 11 and 12, each preferably
have a plastic outer shell reinforced by a metal stiffening
element, as generally indicated in connection with post 11 of FIG.
1. This feature will be described in more detail below. To keep out
moisture and debris, decorative end caps or finials, such as
finials 38 and 39, are placed atop the posts.
[0030] To couple the handrails to the posts upper brackets are
provided, such as brackets 41, 43, 45, and 47. The upper brackets
or handrail brackets are slipped over the ends of the handrails
during assembly and then fastened to the faces of the upright posts
11 and 12 to secure the handrails in place. Likewise, lower
brackets 42, 44, 46, and 48 are provided for coupling the lower
rails to the upright posts. As shown in FIG. 1, the lower brackets
have an opening which is configured to closely receive the ends of
the lower rails, while the upper brackets have openings which are
adapted to closely receive the ends of the handrails.
[0031] As shown in FIGS. 1-3, each of the brackets, such as upper
bracket 43, includes upper and lower flanges 51 and 52 which are
provided to be placed flat against one of the side faces of the
upright posts for mounting thereto. In this regard, the flanges 51
and 52 each include a pair of mounting holes for receiving screws
or bolts or rivets therethrough for fastening the mounting bracket
to the upright post. For example, see fastening holes or mounting
holes 53, 54, 55, and 56. Each bracket also includes an offset face
57 which is parallel to and offset from the flanges 51 and 52. The
offset face 57 includes a shaped opening 58 which is adapted to
closely receive a handrail. Of course, if one changes the shape of
the handrail, the shape of the shaped opening 58 should be changed
correspondingly. Likewise, the rectangular shape of the lower rail
17 indicates the use of a rectangularly shaped opening in the lower
brackets 42, 44, 46, and 48.
[0032] Ramps or angled faces 61 and 62 extend between the flanges
51 and 52 and the offset face 57. Also, side covers, such as side
cover 63 and an unshown side cover, cooperate with the other
portions of the bracket to form a box-like enclosure for shrouding
the ends of the rails. Preferably, the brackets, both the upper
brackets and the lower brackets, are made of metal and are stamped
and bent into shape. Most preferably, the brackets are made of flat
aluminum stock which is formed into shape and then is powder coated
(painted) to match the color of the plastic PVC components. As
shown in FIG. 3, bracket 43 is adapted to cooperate with and
receive handrail 14 when oriented perpendicularly relative to the
upright posts, that is when angle 64 is 90 degrees.
[0033] Handrails, such as handrail 14, are preferably composite
constructions including an outer PVC shell, such as shell 66, and
an internal metal reinforcing element 67. The metal reinforcing
element 67 is generally trapezoidal with one side thereof being
partially open. The metal reinforcing element 67 is made by folding
flat stock and is sized and adapted to be closely fitted within the
interior of the hollow plastic shell 66. The metal reinforcing
element 67 runs longitudinally within the plastic shell 66.
[0034] As shown in FIG. 4A, a bowed connector 405 includes a
mounting flange 435, a perpendicular bracket end portion 445, and
an angled portion 440. The mounting flange 435 is integrally formed
with the end portion 445 and angled portion 440. In this regard, it
is preferred that the bowed connector 405 is injection molded as a
unitary element. The mounting flange 435 includes fastener holes,
not shown in this figure, for securing the mounting flange 435 to
the upright post 412. It should be understood by those skilled in
the art that other means of attaching the bowed connector 405 to
the upright post can be employed.
[0035] The bowed connector 405 is hollow and generally tubular in
construction. The end portion 440 has an opening which matches in
profile the handrail 420 and the lower rail 422. It should be noted
that if the handrail 420 has a different profile (cross-section)
than the lower rail 422, the upper and lower bowed connectors would
have slightly different configurations. That is, the profile
opening in the bowed connectors should match the cross-sectional
profile of the particular rail to be received therein. On the other
hand, if the handrails and the lower rail have the same profile,
then the upper and lower bowed connectors can be identical in their
construction.
[0036] Furthermore, as shown in FIG. 4A, the bowed connectors are
useful for coupling an angled railing to a lower upright post 410
and to an upper upright post 412. If the railings have
top-to-bottom symmetry such that the railing has the same profile
when inverted, identical bowed connectors can be used on the lower
upright post 410 as on the upper upright post 412. The bowed
connectors attached to the upright post 410 are oriented with the
angled end portion 440 pointed up, while the bowed connectors
attached to the upper upright post 412 are oriented with the angled
end portion 440 pointed downwardly.
[0037] FIG. 4B is a cross-sectional view of an example of a bowed
connector 405 illustrating a bread loaf shaped opening 450. In this
example, the opening 450 matches the cross-sectional shape of the
handrail 420.
[0038] FIG. 5 is an enlarged side view of the bowed connector 405
illustrating the relationship between the bowed connector 405 and
railing 500. The railing 500 could be either the handrail 420 or
the lower rail 422. The bowed connector 405 is generally hollow and
includes a cavity 510 defined by non-parallel walls 515. As the
railing 500 is inserted within the bowed connector 405, the railing
500 slides against the walls 515. These walls guide the railing 500
towards the bend 520 in the bowed connector 405. Because the walls
515 are not parallel, the railing 500 slides until it becomes
firmly secured between the walls 515, which secures the railing 500
within the connector 405. While this is effective for securing the
railing, it requires relatively close correspondence between the
angle of the railing and the angle of the end of the bowed
connector. Alternatively, the cavity 510 could include a wall that
encloses the cavity 510 and serves as an anti-jamming mechanism.
For example, the wall can hinder the railing 500 from being
inserted too far within the bowed connector 405. In another
alternative construction, the angled end 440 of the bowed connector
405 could be smaller than the railing 500. Such a bowed connector
405 could be inserted into the railing 500 until secure.
[0039] FIG. 6 shows an alternate construction of the bowed
connector 405. In comparison to the construction shown in FIG. 5,
in which a relatively long corresponding bore is provided to match
the profile of the railing, in the construction shown in FIG. 6 a
relatively short profile opening is provided. The profile opening
is defined by the annular shoulders 605 which define a bore having
a face or surface 606 for receiving and engaging side surfaces of
the railing. One disadvantage to the arrangement of FIG. 6 versus
that of FIG. 5 is that in order provide a good fit, the dimensions
of the opening defined in the bowed connector must be carefully
matched to the profile of the railing. On the other hand, this
construction allows for a greater degree of variance of the angle.
In other words, the axis of elongation of the railing 500 can be
different from the axis of elongation of the end portion or bent
portion of the bowed connector 600 to a greater extent than in the
prior embodiment. This is so because by guiding the railing only at
the surface 606, the railing has clearance within the bowed
connector 600 and therefore can be tilted more upright or less
upright and still be accommodated within the bowed connector
600.
[0040] FIG. 7 shows another alternate construction of the bowed
connector. In this figure, the annular shoulders are shown as
having a radiused surfaces. This further helps provide greater
annular flexibility, while still maintaining a reasonably good
gripping securement of the railing 500. For example, as shown in
dashed lines in FIG. 7, the railing 500 can have a substantial
angular deflection from the angled portion of the bowed
connector.
[0041] While the invention has been disclosed in preferred forms,
it will be apparent to those skilled in the art that many
modifications, additions, and deletions can be made therein without
departing from the spirit and scope of the invention as set forth
in the following claims.
* * * * *