U.S. patent application number 10/632778 was filed with the patent office on 2004-02-12 for post and railing construction.
Invention is credited to Terrels, Andrew P., Terrels, Christopher J..
Application Number | 20040026679 10/632778 |
Document ID | / |
Family ID | 31498610 |
Filed Date | 2004-02-12 |
United States Patent
Application |
20040026679 |
Kind Code |
A1 |
Terrels, Christopher J. ; et
al. |
February 12, 2004 |
Post and railing construction
Abstract
A post and railing construction permits construction of fences
and railings from parts which are pre-molded from a resinous
material such as rigid polyvinyl chloride (PVC). The parts require
no painting and are not prone to corrosion or rust when exposed to
harsh environments. The posts have a rigid upright core element
with a hollow shell mounted on the core element by one or more
frames. In one embodiment of the invention, railings are supported
on brackets mounted on the frames of the posts. In another
embodiment of the invention, railings are supported directly on the
frames of the posts by routed openings in the hollow shell. The
present invention also provides an easy to assemble fence assembly
having the appearance and style of a picket fence. Exterior
fasteners may be covered with optional caps to avoid direct
exposure to damaging elements, such as moisture.
Inventors: |
Terrels, Christopher J.;
(Ocean City, NJ) ; Terrels, Andrew P.; (Marmora,
NJ) |
Correspondence
Address: |
DANN, DORFMAN, HERRELL & SKILLMAN
1601 MARKET STREET
SUITE 2400
PHILADELPHIA
PA
19103-2307
US
|
Family ID: |
31498610 |
Appl. No.: |
10/632778 |
Filed: |
August 1, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60400294 |
Aug 1, 2002 |
|
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Current U.S.
Class: |
256/65.03 |
Current CPC
Class: |
E04H 17/1447 20210101;
E04H 17/1439 20130101 |
Class at
Publication: |
256/65.03 |
International
Class: |
E04H 017/00 |
Claims
I claim:
1. A post and railing assembly comprising a cylindrical core; a
rectangular frame configured for securing around the core; a
rectangular shell having an inner surface and an outer surface,
said inner surface being configured for engagement with the
rectangular frame; a railing comprising a railing end configured
for coupling with the outer surface of the rectangular shell; and a
bracket on the outer surface of the shell, said bracket forming a
socket adapted to receive said railing end to secure said railing
to the shell core through the shell.
2. The post and railing assembly of claim 1, wherein the frame
comprises two frame halves each having a semicircular inner face, a
generally rectangular outer face, and one or more frame fasteners
that connect the frame halves together in a clamped arrangement
around the core, said semicircular inner faces adjoining one
another in the clamped arrangement to form a cylindrical surface
that frictionally engages the core, said rectangular outer faces
forming a continuous outer skirt that engages the inner surface of
the shell.
3. The post and railing assembly of claim 1, wherein the shell,
frames and brackets are formed of rigid polyvinylchloride.
4. The post and railing assembly of claim 1, wherein the bracket
comprises a plurality of resilient flexible spring sheets in the
socket, said spring sheets being biased inwardly and configured to
impart inward pressure on the railing end when the railing is
inserted in the socket.
5. The post and railing assembly of claim 1, wherein the bracket
comprises a cylindrical hole that extends through the bracket, said
hole being adapted to receive a bracket fastener that extends
through the hole and the shell and into said frame to secure the
bracket on the cylindrical core against the outer face of the
shell.
6. The post and railing assembly of claim 5, wherein the bracket
fastener is configured to interconnect the frame, shell and bracket
with said core.
7. The post and railing assembly of claim 1, comprising a generally
cylindrical cover configured for insertion into the hole in the
bracket, said cover having a resiliently flexible side wall and an
end wall, said side wall when separated from the hole having a
diameter that is slightly larger than the diameter of the hole and
a longitudinal slot extending though the side wall of the cover,
said side wall further being inwardly flexible to permit the cover
to be inserted into the hole to enclose the fastener, said cover
being inserted into the hole in a compressed condition in which the
side wall is biased outwardly into frictional engagement with the
interior wall of the hole.
8. The post and railing assembly of claim 7, wherein the bracket
has an exterior contour, and the end wall of the cover has an
exterior face that conforms to the exterior contour of the brackets
surrounding the hole.
9. The post and railing assembly of claim-7, wherein said hole
comprises an interior wall and a tongue projection extending along
the interior wall, said tongue projection configured to mate with
said longitudinal slot when the cover is inserted in the hole to
limit rotational displacement of the cover relative to the interior
wall of the hole.
10. The post and railing assembly of claim 7, wherein said hole
comprises an interior wall and an aperture extending through the
interior wall, said cover comprising a resilient flexible spring
tab having a tapered face that slidably engages the interior wall
of the hole as the cover is inserted into the hole, said spring tab
being configured to flex inwardly in a biased condition during
insertion into the hole and snap outwardly when the spring tab is
aligned with the aperture in the interior wall of the hole.
11. A post and railing assembly comprising a cylindrical core; a
rectangular frame configured for securing around the core; a
rectangular shell having an inner surface and an outer surface,
said inner surface being configured for engagement with the
rectangular frame; and a railing comprising a railing end
configured for engaging the rectangular shell, said frame providing
vertical support for said railing end on said cylindrical core.
12. The post and railing assembly of claim 11, wherein the frame
comprises two frame halves each having a semicircular inner face, a
generally rectangular outer face, and one or more frame fasteners
that connect the frame halves together in a clamped arrangement
around the core, said semicircular inner faces adjoining one
another in the clamped arrangement to form a cylindrical surface
that frictionally engages the core, said rectangular outer faces
forming a continuous outer skirt that engages the inner surface of
the shell.
13. The post and railing assembly of claim 12, wherein the shell
and frame are formed of rigid polyvinylchloride.
14. The post and railing assembly of claim 11, wherein the shell
comprises an opening that conforms with the shape of the railing
end, said opening being adapted to receive the railing end and
position said railing to be vertically supported by said frame
halves.
15. A bracket for coupling a railing member to a supporting
structure, said bracket comprising a socket adapted to receive the
end of the railing member and having a plurality of resilient
flexible spring sheets that are biased inwardly in the socket, said
spring sheets being configured to impart inward pressure on the
railing end when the railing is inserted in the socket to secure
the railing end in the socket.
16. The bracket of claim 15, comprising a rear face that forms a
notch adapted to conform to a corner on the supporting
structure.
17. The bracket of claim 15, comprising a curved rear face adapted
to conform to a curved surface on the supporting structure.
18. A bracket for coupling a railing member to a post structure,
said bracket comprising a socket adapted to receive the end of the
railing member and at least one hole for receiving a bracket
fastener, said bracket fastener being configured to extend through
the hole to connect the bracket to the post structure, a generally
cylindrical cover adapted to be inserted in said hole and having a
resiliently flexible side wall and an end wall, said side wall
having a diameter when separated from the hole that is slightly
larger than the diameter of the hole and a longitudinal slot
extending though the side wall, said side wall further being
inwardly flexible to permit the cover to be inserted into the hole
to enclose the fastener, said cover being inserted into the hole in
a compressed condition in which the side wall is biased outwardly
into frictional engagement with the interior wall of the hole.
19. The bracket of claim 18, wherein the bracket has a curved
exterior contour surrounding said hole, and the end wall of the
cover has an exterior face with a curvature that conforms to the
curved exterior contour of the bracket.
20. The bracket of claim 18, wherein said hole comprises an
interior wall and a tongue projection extending along the interior
wall, said longitudinal slot configured to mate with said tongue
projection when the cover is inserted in the hole to limit
rotational displacement of the cover relative to the interior wall
of the hole.
21. A post and railing assembly comprising a cylindrical core; a
frame configured for securing around the core, said frame
comprising a tubular center section and a plurality of support fins
extending radially outwardly from the tubular center section; a
rectangular shell having an inner surface and an outer surface,
said inner surface being configured for engagement with the support
fins on the rectangular frame; a railing comprising a railing end
configured for coupling with the outer surface of the rectangular
shell; and a bracket on the outer surface of the shell, said
bracket forming a socket adapted to receive said railing end to
secure said railing to the shell core through the shell.
22. The post and railing assembly of claim 21, comprising a
plurality of corner flanges extending outwardly from the support
fins, said corner flanges being configured to engage the inner
surface of the rectangular shell.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of
U.S. Provisional Application No. 60/400,294, filed Aug. 1, 2002,
the entire disclosure of which is incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to post and railing
assemblies, and more specifically to post and railing assemblies
with standard prefabricated parts.
BACKGROUND OF THE INVENTION
[0003] Post and railing fences have traditionally been constructed
using a variety of timber, including pine and cedar. Although
timber is a reasonably sturdy material, timber wears down over
time, yielding to extreme weather conditions, prolonged rotting,
termite infestation, and other factors. Even treated timber can
experience rotting and warping. The development of
polyvinylchloride (PVC) and other plastics has led to the use of
plastics in post and railing assemblies. Although plastic railing
materials are more durable than timber in many respects, known
plastic railing systems have some drawbacks. For example, some
plastic systems include a large number of fasteners and parts that
make installation difficult and costly. In addition, many plastic
railing systems include visible fasteners and seams that detract
from the appearance of the railing system. The components in some
plastic railing systems do not permit reliable or secure
connections between components. Based on these drawbacks, there is
a clear need for plastic railing systems that are economical to
install, aesthetically pleasing, and securely constructed.
SUMMARY OF THE INVENTION
[0004] A post and railing construction in accordance with the
present invention permits construction of fences and railings from
parts which are pre-molded from a resinous material such as rigid
polyvinyl chloride (PVC). The parts require no painting and are not
prone to corrosion or rust when exposed to harsh environments. In
addition, the parts are configured to be used on a number of
different railing and fence assemblies.
[0005] In one embodiment of the invention, railings are supported
on brackets mounted on posts. In another embodiment of the
invention, railings are supported directly on the posts by routed
openings in the posts. The present invention also provides an easy
to assemble fence assembly having the appearance and style of a
picket fence. Metal components that are used in the invention may
be covered to avoid direct exposure to damaging elements, such as
moisture. For example, the railing construction may be provided
with covers that are placed over screws to protect the screws and
hide them from view.
[0006] Posts are provided having a uniform square or rectangular
flat-sided structure. The posts are formed of a tubular shell,
preferably having a square or rectangular internal surface similar
to the exterior surface. The shell has a relatively thin rigid wall
and may be reinforced along its length by a plurality of internal
frames. The frames are configured to engage the internal surfaces
of the shell and slide along a central cylindrical core such as a
pipe, which may be made of tubular steel or other strong
material.
[0007] In erecting the posts, the core is solidly connected to the
ground, a floor, a deck or other base structure. This can be done
by conventional means by embedding the core pipe in concrete or
other solid material, or by mounting the core pipe to a base with
brackets and/or fasteners. A simple cap, such as a pyramidal
closure or other decorative shaped cover may be attached to the top
of the shell. The cap may snap on and slide off of the shell, and
be interchanged with different cap configurations to modify the
appearance of the assembly. The support frames are slidable along
the length of the core pipe to allow adjustment of the frames to a
desired height. One frame member may be positioned at the top of
the pipe and one frame positioned at the bottom of the pipe. Once
the frames are adjusted to the proper positions, the frames may be
secured to the pipe. The outside of the frame means may either
provide a conforming pattern to the internal cross-section of the
shell or sufficient contact points with the shell to keep the shell
oriented in a predetermined position once that position has been
selected and the frames anchored to the post. Anchoring can be
accomplished in a variety of ways, such as by using bolts. The
frames may be formed in two pieces that are connected around the
core pipe in a clamp-like arrangement. Initially, the two frame
pieces may be bolted together loosely to allow the assembled frame
to be axially adjusted on the pipe and placed in proper position.
Once the frame pieces are properly positioned, the bolts may be
tightened to stabilize the frame in frictional engagement with the
pipe.
[0008] The railing can be assembled by measuring the desired
distance between posts and erecting the core pipes at desired
locations. The lower frames are then positioned on the posts, and
the shell is placed over the frames. Once the orientation of the
shell is properly set, the lower frame is tightened in place. Upper
frames may then be attached to the post and aligned based on the
orientation of the lower frame and the shell. Once the upper frame
is in proper position, it is tightened to the core pipe, similar to
the lower frame. After the shell is installed over the frames,
brackets may be anchored to the shell and frames with fasteners. In
addition to anchoring the shell on the core pipes, the brackets are
configured to support rails between posts.
[0009] When screws are used with brackets, the screws are placed in
cylindrical openings in the brackets. A narrow shoulder may be
provided on the interior of the openings at the inner most end. The
cylindrical openings may be hidden or made less apparent by covers.
The covers may be formed of resinous material and have a generally
cup-shaped structure with cylindrical sidewalls. The sidewalls may
be configured to fit snugly within the cylindrical openings. An end
of each cover may conform to the exterior contours on the bracket
to hide or minimize notice of the screw hole and cover.
[0010] In a second embodiment, railings are secured directly to
posts through routed or punched openings that conform to the
geometry of the rails. The rails assist in securing the shells in
place on the posts. The rigid railing or fence panel arrays extend
through the holes and are anchored between frames secured to the
core to limit displacement of the shell.
[0011] In a third embodiment, a picket fence assembly is provided.
A special resilient cleat made of resinous material attached at one
end to horizontal fence or railing members is designed to fit
within a tubular picket at a conforming hole. The cleat has a cam
surface which acts as a latch to mount the picket to the rail. A
number of cleats may be coupled with the rails to provide latching
arrangements between the rails and a series of pickets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The embodiments of the present invention may be better
understood by reference to the accompanying drawings, in which:
[0013] FIG. 1 is a perspective view of a railing employing various
structures in accordance with the present invention;
[0014] FIG. 2 is an exploded perspective view showing one
arrangement for attachment of railings to posts using external
brackets;
[0015] FIG. 3 is a drawing in section taken on the line 3-3 of FIG.
2 assembled and the internal structure of the post;
[0016] FIG. 4 is an enlarged exploded perspective exploded view of
pieces of a support frame, several of which are seen assembled and
in position in FIGS. 2 and 3;
[0017] FIG. 5 is an enlarged perspective view of a first bracket
variation mountable to a vertical post for receiving and supporting
a handrail or other railing shaped with a specific cross-sectional
shape;
[0018] FIG. 6 is a perspective view of a second bracket variation
used for supporting a square lower rail of the railing structure in
FIG. 1 on a flat vertical surface of a post;
[0019] FIG. 7 is a perspective view of a third bracket variation
used for supporting a rectangular lower rail of the railing
structure in FIG. 1 on the corner of a vertical post;
[0020] FIG. 8 is a perspective view of a fourth bracket variation
for use in supporting a rectangular rail on the rounded exterior of
a cylindrical post.
[0021] FIG. 9 is a cross-sectional view in partial section at the
upper support frame taken along the line 9-9 in FIG. 10;
[0022] FIG. 10 is a partial sectional view taken along line 10-10
in FIG. 9;
[0023] FIG. 11 is a perspective view of a molded resinous screw
cover designed to latch in a pop-in fitting on a bracket of the
type shown in FIGS. 5-8 and FIG. 28;
[0024] FIG. 12 is a plan view from above the screw cover of FIG.
11;
[0025] FIG. 13 is a side elevation view of the screw cover of FIGS.
11 and 12;
[0026] FIG. 14 is a front elevation view of the screw cover of
FIGS. 11-13;
[0027] FIG. 15 is an exploded perspective view showing a second
arrangement for attaching railings to posts using routed or punched
openings in one of the faces of the post shell;
[0028] FIG. 16 is a sectional view taken on the line 16-16 of FIG.
15, showing the post and railings of FIG. 15 assembled and the
internal structure of the posts;
[0029] FIG. 17 is an enlarged exploded perspective view of pieces
of a support frame, two of which are seen assembled and in position
in FIG. 16;
[0030] FIG. 18 is a perspective view of an assembled railing in
accordance with the structure seen in FIGS. 15-17;
[0031] FIG. 19 is an exploded perspective view of a picket fence
assembly showing an arrangement for attachment of railings to posts
using external brackets and showing means of attachments of pickets
to the railings;
[0032] FIGS. 20 and 21 are perspective views from different angles
showing the shape and nature of a resilient cleat attached to
horizontal fence or railing members to permit easy attachment of
individual pickets thereto;
[0033] FIG. 22 is a sectional view of the cleat of FIGS. 20 and 21
showing the cleat in a position for attachment to a picket, similar
to the position assumed in FIG. 25;
[0034] FIGS. 23, 24, 25, and 26 are partial sectional views taken
in a vertical plane through a railing and picket showing sequential
steps in the attachment of the picket to the railing using the
cleat of FIGS. 20-22;
[0035] FIG. 27 is a perspective view of an assembled picket fence
in accordance with the present invention;
[0036] FIG. 28 is a perspective view of a fifth bracket variation
for use in supporting a rectangular rail and having an edge that
may be customized to conform to the exterior shape of a supporting
structure;
[0037] FIG. 29 is an exploded perspective view showing a frame
variation for use in connecting external brackets to a post.
[0038] FIG. 30 is sectional elevation view of the support frame of
FIG. 29 with railings connected with the support brackets.
[0039] FIG. 31 is a cross sectional view of the support frame shown
in FIG. 29 in use with an optional channel member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] Referring first to FIGS. 1-3, a railing assembly comprises a
series of vertical posts with railing arrays extending horizontally
between the posts. Each array includes one and preferably a
plurality of horizontal rails. The arrays may be reinforced by
vertical spacers secured between the rails. This embodiment
illustrates different external brackets that can be mounted on
posts 20 to produce an arrangement having a railing array 12
disposed at a 450 angle relative to adjacent flanking arrays 14 and
16. The post comprises a vertical support 36 enclosed within a
hollow shell 20a. The shells 20a for the posts may be formed from
extruded hollow square tubular shells, with peaked square pyramidal
caps 18 closing the top of each shell. It will be appreciated,
however, that other geometrical shapes and designs may be used for
the shells and caps. The handrail arrays of the present invention
are constructed from extruded hollow rigid parts of polyvinyl
chloride resin (PVC), or other resin which is easily formulated,
mixed and molded to the various cooperating pieces required from
which then may be assembled into unitary railing panels or arrays.
One of the advantages of structures in accordance with this
invention is that there are no exposed metal surfaces requiring
painting or other maintenance. The exposed parts are either PVC, or
parts covered with PVC, which are not prone to corrosion or other
forms of deterioration associated with metal surfaces. Other types
of resinous materials, as suggested, may be used. However, PVC has
the advantage of being structurally strong and rugged, inexpensive,
easily handled, and provides an attractive finish which does not
have to be painted. It can be colored by additives. Additives may
also be used to strengthen the PVC. In this case, where external
brackets are employed, as will appear, the screws may be covered to
protect the screws against corrosion and improve the aesthetic
appearance of the assembly.
[0041] The external brackets are used to connect each railing array
to a post 20. The brackets may be attached to the post by bolts, or
other conventional means, as will appear hereafter. In FIG. 1, the
assembled railing has a pair of end posts and a pair of
intermediate posts. The end posts and intermediate posts are
arranged relative to one another so that the square shells have the
same orientation. Fencing arrays 14 and 16 have rails that abut
flat surfaces on the post shells 20a. Therefore, the posts
supporting arrays 14 and 16 have brackets 32 and 34, which are
designed to fit on flat surfaces. The array 12 has rails that
intersect corner edges on the intermediate posts. Therefore, the
intermediate posts have brackets 22 and 24, which are designed to
fit on a corner surface of the shell 20a.
[0042] Referring now to FIGS. 2 and 3, the top rail 26 is
configured as a guard rail, and the bottom rail 28 has a square or
rectangular cross-section. A vertical spacer structure 30 connects
the rails 26 and 28. The railing configuration may be prefabricated
in arrays of standard lengths. Railing shapes and types may be
designed to conform to standard cross-sections, and supporting
brackets such as brackets 32 and 34 have openings designed to
receive and support the ends of their respective rails, as seen in
FIGS. 2 and 3.
[0043] The support brackets 32 and 34 are configured to mount on a
side face of a post, as discussed above. In particular, brackets 32
and 34 are designed to fit on flat surfaces of a standard post
shell 20a. Bracket 32 is shown in more detail in FIG. 5, and
bracket 34 is shown in more detail in FIG. 6. Railing arrays that
are angularly offset from adjacent arrays, such as array 12 in FIG.
1, may require different brackets that mount on the corner of post
shells. In FIGS. 1 and 7, alternate brackets 22 and 24 are shown.
Brackets 22 and 24 have V-shaped notches that conform to the
surface contour of the corners on each post shell 20a. In this way,
the brackets 22 and 24 are configured to mount flush against the
corner of each post shell 20a. Other bracket configurations may be
used to mount railings on different supporting structures. In FIG.
8, a bracket 74 is shown which has a rounded cut 76. The rounded
cut 76 is configured to conform to the rounded exterior of a
cylindrical column or other support structure with a circular
curvature. In FIG. 28, a bracket 84 has a flat rear face 86 of
sufficient depth so that may be cut and shaped in the field to
conform to the geometry of a supporting structure. Both brackets 74
and 84 may include cylindrical holes 54 for receiving mounting
screws, as will be described in more detail below.
[0044] The design of the vertical shells 20a is intended to produce
high strength supports having a uniform appearance. Each post 20
has a high strength structural core 36 which may be formed of a
variety of structural materials. For instance, the core 36 may be
formed out of cylindrical steel pipe. The core 36 is configured to
support one or more frames that may be mounted on the core to
anchor the shells 20a to the core. The cores 36 may be supported in
any conventional manner. For example, the cores 36 may be embedded
in a concrete floor or deck. Alternatively, the cores 36 may be
supported by attaching them through brackets to a wooden deck or
floor which accepts screws or bolts to anchor the cores in place.
The hollow, vinyl shell 20a may have a square cross-section, but
can also be made in other shapes if desired. Whatever the shape, it
is desirable to have a hollow inner surface that is uniform in its
cross-section. The dimensions of the shell are otherwise determined
by the scale of the actual fence or railing being supported. The
space between the shell 20a and the core 36 may be bridged by a
plurality of structured support frames.
[0045] Referring to FIG. 4, a two piece frame 38 is shown,
comprising pieces 38a and 38b. The pieces 38a and 38b are
preferably identical in configuration such that any two frame
pieces are compatible with one another. The frames 38 are
preferably molded using a high strength material. As seen in FIG. 4
as well as FIGS. 9 and 10, the two pieces 38a and 38b combine to
form a tubular collar 40. The pieces may be connected to form the
frame 38 using a variety of fasteners, including but not limited to
screws, or nuts and bolts. In FIGS. 9 and 10, the frame pieces are
shown connected with a plurality of nuts and bolts 42. The nuts and
bolts 42 are inserted through opposing vertical webs 44a and 44b on
the frame pieces and threaded together to connect the frame pieces.
The engagement between the nuts and bolts 42 may be adjusted to
control the fit between the frame 38 and the core pipe 36. In
particular, the nuts and bolts 42 may be connected in a loose
setting to allow the collar 40 to slide axially along the core 36
and permit the frame to be set at the proper position on the core.
Once the frame is properly positioned, the nuts and bolts 42 may be
tightened to produce an interference fit between the tubular core
36 and the collar 40 to frictionally hold the frame 38 in a
selected axial and rotational position on the core. Until the bolts
42 are tightened, the support frame 38 is rotatable about the core
36 to allow the shell 20a to be properly oriented. Referring now to
FIG. 10, the support frame 38 is provided with a peripheral skirt
46 which conforms to the interior cross-sectional shape of the
shell 20a. The skirt 46 is configured to slidably engage the
interior surface of the shell 20a. The peripheral skirt 46 may have
any geometry configured to slidably engage the interior of the
shell. Preferably, the skirt's configuration engages the interior
of the shell such that the orientation of the shell is stable and
resists rotational displacement. The collar 40 and the outer skirt
46 may be connected by a horizontal web 48 divided into pieces 48a
and 48b, as shown in FIG. 4. Reinforcing ribs connect between the
peripheral skirt 46 and web pieces 48a, 48b to increase the
rigidity of the frame 38.
[0046] As seen in FIG. 3, the support frames 38 determine the
orientation of the post shell 20a. In assembly, the vertical core
pipe 36 is first secured in place. In the specific case of the
structure of FIGS. 2 and 3, two support frames are arranged along
the core pipe 36 in substantial alignment with the vertical
position of the bottom rail 28. The two frames are inverted
relative to one another and butted together to support the bracket
for the bottom rail 28. After the two frames are adjusted to the
correct level and rotated to the proper orientation, the collars 40
may be tightened against the core pipe 36 using the nuts and bolts
42. The shell 20a is then placed over the frames. Once the shell
20a is in place, the upper support frame 38 is placed around the
core pipe 36 and partially secured so that the frame is free to
slide up and down the core pipe. The relative position of the upper
frame 38 on the pipe 36 is adjusted until the position of the frame
is generally aligned with the position where the railing will
intersect the shell. Once the upper frame 38 is properly adjusted,
the upper frame may be tightened in place. The brackets 32 and 34
can then be secured to the shell 20a using screws 50 and 52.
Referring to FIGS. 3 and 6, the bracket 34 is connected to the post
shell 20a by four screws 50. The screws 50 are anchored into the
shell 20a and the peripheral skirt 46 of the support frames. The
bracket 32, as best seen in FIG. 5, is anchored by two screws.
[0047] It is noted that the frames are securely mounted on the
upright core 36 to provide a firm lateral support for the shell
20a. The positions of the frames 38 in registry with the upper and
lower rails 26 and 28 enables the brackets to be firmly supported
by the core 36 and the frames 38 and to provide secure vertical
support for the rails 26 and 28.
[0048] In some cases, it may be desirable to have one solid support
frame along the length of the core. Referring to FIGS. 29-31, a
one-piece support frame 338 is shown which connects a shell 320
around a structural core element 336. The support frame 338 has a
tubular section 340 and a plurality of support fins 342 extending
radially outwardly from the tubular section. The tubular section
340 is adapted for sliding over the core 336. The support frame 338
may be inserted over the entire length of a core, or sections of
the core. In FIGS. 29-30, the support frame 338 extends along a
substantial portion of the core 336 and is configured to permit the
mounting of one or more brackets to the post structure. Since the
one-piece support frame 338 extends along a substantial portion of
the core element 336, brackets can be easily mounted to the support
frame and column at almost any position on the post structure.
[0049] The tubular section 340 of the support frame 338 preferably
contacts the exterior of the core 336 in a tight frictional
engagement. The frictional engagement provides resistance against
rotation so that the frame can be set to the proper orientation on
the core and resist further rotation from incidental bumps during
installation. Frictional engagement may be provided in a number of
ways. For example, the inner diameter of the tubular section may be
substantially equal to the outer diameter of the core 336 so as to
form a snug connection. Alternatively, the inner diameter of the
tubular section 340 may include one or more longitudinal ribs 346,
as shown in FIG. 31. The ribs 346 extend radially inwardly from the
interior wall of the tubular section and frictionally engage the
exterior of the core 336 to provide a snug fit. The support frame
338 may be secured to the core 336 by one or more fasteners, if
desired. In FIG. 31, a screw 345 is mounted through the wall of the
tubular section 340 and through the core 336 to secure the support
frame 338 to the core. The support frame 338 is preferably
extruded, but may also be formed from one or more molded
components.
[0050] A corner flange 343 extends from the outward end of each
support fin 342. The corner flanges 343 are configured to engage
the inner wall of the shell 320 and provide a backing surface for
mounting support brackets to the shell with one or more fasteners.
In FIGS. 29-30, the support brackets 332, 334 are mounted to the
shell with a plurality of screws. Each screw extends through the
shell 320 and into two separate sections of the support frame. More
specifically, each screw extends through a corner flange 343 and a
support fin 342, as shown in FIG. 31.
[0051] The interior wall dimensions of the shell 320 are slightly
larger that the exterior dimensions of the support frame, providing
a clearance space between the support frame 338 and shell.
Preferably, the support frame 338 includes gaskets or friction
elements 352 on the edges of the corner flanges. The friction
elements are configured to extend through the clearance space and
frictionally engage the interior of the shell 320 so that the shell
fits snugly around the support frame. In this arrangement, the
frictional engagement reduces the potential for rattling or
incidental shifting of the shell around the support frame. The
friction elements 352 may be formed of rubber or other flexible
material. In addition, the friction elements 352 may be connected
with the corner flanges by an extrusion process, an adhesive, or
other technique.
[0052] Referring to FIG. 31, an optional channel member 350 may be
inserted into the post structure to provide an additional backing
surface for mounting support brackets to the shell. The channel
member 350 is disposed between adjacent corner flanges 343 and
abuts the interior wall of the shell in a flush arrangement with
the corner flanges. Like the support frame 338, the channel member
350 may be manufactured in different lengths and be inserted along
the entire length of the core 336, or along sections of the
core.
[0053] The support frame 338 may be installed as follows. After the
core 336 is mounted to a base support, the support frame 338 is
held over the core with the tubular section 340 aligned with the
core. The support frame 338 is then lowered over the core and
advanced down the core until the support frame is placed at the
desired position on the core. Once in the desired position on the
core, the support frame is rotated to the desired orientation
corresponding to the desired orientation of the shell. At this
time, a screw or other fastener may be inserted through the tubular
section 340 and into the core 336 to fix the orientation of the
support frame. The shell 320 is then slid down over the support
frame 338 with the inner walls of the shell in alignment with the
corner flanges 343 on the support frame. If desired, a channel
member 350 may be inserted into the interior of the shell on the
side where brackets will be mounted. The channel member 350 is
inserted through the open top end of the shell and advanced
downwardly into the shell between two of the support fins on the
support frame. The top end of the post structure may then be closed
with a cap to enclose and conceal the interior components of the
post.
[0054] Referring to FIGS. 5-8 and 28, the brackets 22, 24, 32, 34,
74 and 84 have sufficient depth to support a rail in a stable
position between a pair of posts. The rails may be further
stabilized by providing resilient spring sheet surfaces in the
brackets, such as spring sheets 22a, 32a, 34a, 74a and 84a. The
spring sheets are molded into the brackets and extend into the
sockets that receive the ends of the railings. An integral web of
resilient material is cantilevered from the frame wall so that the
spring sheets extend inwardly toward the rail when the rail is
received in the slot. The spring sheets are biased inwardly and
impart inward pressure on the rail ends to produce a snug fit
between the rails and the brackets.
[0055] Referring to FIG. 3, the screws 50 and 52 are mounted
through the brackets 32 and 34 and driven into the frames 38 from
the exterior of the shell 20a. It may be desirable to cover the
screws 50 and 52 so that the screws are protected from adverse
elements, such as moisture, which can cause the screws to corrode.
Covers may also be used to hide the screws, improving the aesthetic
appearance of the assembled railing. FIGS. 11-14 show one
embodiment of a cover 56 that may be used to cover the screws 50
and 52. The cover 56 is configured to be inserted in any of the
mounting brackets of FIGS. 5-8 and 28. The cylindrical holes for
receiving the screws have all been similarly designated by number
54. The covers 56 shown in each of the drawings have cylindrical
side walls 56a which are closed with a curved end wall 56b. The end
wall 56b is configured to conform to the exterior contour of the
bracket at each opening. As best seen in FIG. 12, each cover has at
least one slot 56c which allows the side walls of the cover to flex
inwardly as the cover is inserted into a hole 54. The covers 56
have a pair of tapered spring tabs 58. The tapered edges of the
spring tabs 58 are configured to flex the side walls inwardly as
the spring tabs engage the interior of the holes 54. Once the
covers 56 are inserted in the holes 54, the resilient side walls of
the covers bear outwardly against the interior of the holes to
provide a snug fit. The holes 54 contain one or more tongue like
projections 61 that conform to the shape of the slots 56c and mate
with the slots as the covers are inserted into the holes. The
bottom of the covers 56d are flat cylindrical surfaces which mate
with flat cylindrical shoulders inside the hole so as to cover the
screws in a flush engagement.
[0056] The exterior of the brackets 22, 24, 32, 34, 74 and 84 have
a curved surface 53 surrounding the cylindrical holes 54. The
surface 53 exhibits a compound curvature. For manufacturing
economies, the curved surfaces 53 around every cylindrical hole 54
on each bracket have the same configuration, which conforms with
the curvature of the surface of the end walls 56b of the covers 56.
Thus, any cover 56 may be used with any one of the brackets to
provide a substantially smooth and aesthetically pleasing
appearance to the assembly.
[0057] Referring now to FIGS. 15-18, an alternate embodiment of the
invention is shown. In FIG. 15, a post 120 is shown having a shell
with routed or punched openings 122 and 124 to receive rails 126
and 128, respectively. In most cases, the components that
correspond to components in the previous embodiment are identified
by the same reference numbers increased by 100.
[0058] Routed opening 122 is configured to conform to the shape of
the handrail 126, and routed opening 124 is generally rectangular
to accommodate the respective cross-sectional shape of bottom rail
128. Referring to FIG. 16, there is only one support frame 138
fixed in place near the bottom of the tubular core 136. The bottom
frame 138 is aligned with the bottom of the routed hole 124 so that
the frame and bottom edge of the hole provide vertical support to
the bottom side of the rail 128. The rail 128 engages the sides of
the routed hole 124 to prevent the shell 120 from moving axially
relative to the core 136. Rails 126 and 128 are inserted directly
into the routed holes 122 and 124, respectfully, and abut the
tubular core 136. The upper support frame 138 is brought down into
contact with the top of the handrail 126, thereby clamping the
entire rail array or panel in place between the two support frames
138. If desired, additional screws may be anchored through the
upper support frame 138 and into the rail 126 and/or into the core
pipe 136 to further solidify and anchor the end of the rail
structure. It may be desirable to insert the ends of the rails 126
and 128 through the routed openings after the lower support frame
138 has been secured on the core pipe 136 but before the upper
support frame is secured on the core pipe. In this way, a
relatively snug fit between the ends of the rail array and the core
pipe 136 can be obtained. Referring now to FIG. 17, the same
support frame construction is used as in FIG. 4. A completed
assembly with routed rail supports is shown in FIG. 18.
[0059] Referring now to FIGS. 19-27, a third embodiment of the
invention is shown. This embodiment relates to a picket fence
assembly. In general, components that correspond to components in
the first embodiment are identified by the same reference numbers
increased by 200. Referring to FIG. 19, external brackets 234
similar to those in the first embodiment are used to connect a pair
of rails 59 to a post 220. The rails 59 may have any
cross-sectional shape. In FIG. 19, the rails 59 are shown having
rectangular shapes. The upper rail 59 and bracket 234 are secured
to a pair of frames 238 through the shell 220. The bottom rail 59
and lower bracket 234 are secured to a pair of frames 238 in a
similar manner.
[0060] In a preferred arrangement, individual pickets 64 are
attached to both the top and bottom rails 59 using a spring cleat
60 cast from resilient polymeric resin. The cleat 60 has a simple
configuration, as seen in FIGS. 20, 21 and 22. In particular, the
cleat 60 consists of a body of molded resilient resin, preferably
provided with a recess 60a in the back to minimize the weight and
bulk and improve the flexibility while preserving the strength of
the clip. A single hole 60b passes through the bottom of the cleat
60 and may be threaded if desired, as shown in FIGS. 20 and 21. The
cleats 60 are preferably attached to each of the rails 59 using a
self-tapping screw 62. The cleats 60 are provided with a camming
surface 60c. A channel 60d extends below the camming surface 60c.
The upper edge of channel 60d is terminated below the camming
surface 60c in a latching shoulder 60e. Once installed in the
railing 59, the cleat 60 cooperates with the pickets 64 to hold
them in place on the railing.
[0061] The pickets 64 may be installed after the rails 59 are
connected between adjacent posts 220. Alternatively, the pickets
may be pre-assembled to rails to form a panel or array which is
installed as a unit between posts. Cleats 60 are attached to the
upper and lower rails 59 at incremental spacings corresponding to
the desired spacing between individual pickets 64. Referring to
FIG. 23, each picket has a pair of openings 66 and 66a. To connect
the pickets 64 to the rails, the pickets are brought into position
with the openings 66 and 66a facing the rails 59. The pickets 64
are then moved into position against the rails 59, as shown by the
arrow in FIG. 23. Each picket 64 is placed over a cleat 60. The
openings 66 in each picket 64 are adapted to receive the cleats
such that the picket covers the cleats when assembled to the rails.
The cleats 60 are configured to pass through the openings 66 in the
pickets 64 and secure the pickets against each rail 59. After the
picket 64 is placed over the cleats 60, as shown in FIG. 24, the
picket is slid downwardly relative to the rail 59, as shown by the
arrow in FIG. 25. As the picket 64 is slid downwardly relative to
the rail 59, the camming surface 60c engages the interior of the
picket. The camming surface 60c is tapered radially inwardly toward
the top of the cleat such that the engagement between the camming
surface and the interior of the picket displaces the cleat 60
outwardly and away from the rail 50a. More specifically, the
tapered camming surface 60c contacts a bridge 66b between opening
66 and opening 66a on the picket. After the camming surface 60c
passes over the bridge 66b, the resilience of the cleat 60 causes
the cleat to snap back into its original position relative to the
rail 59 so that the camming surface extends into the smaller
opening 66a, and the latch shoulder 60e engages the bridge 66b, as
shown in FIG. 26. Since the pickets 64 attach to both rails 59 in
the same way, the picket 64 may be attached to both rails in one
downward movement. Subsequent pickets may be attached in sequence
to the rails using pre-installed cleats 60 to form an array
resembling a picket fence, as shown in FIG. 27.
[0062] The terms and expressions which have been employed are used
as terms of description and not of limitation. There is no
intention in the use of such terms and expressions of excluding any
equivalents of the features shown and described or portions
thereof. It is recognized, therefore, that various modifications
are possible within the scope and spirit of the invention.
Accordingly, the invention incorporates variations that fall within
the scope of the following claims.
* * * * *