U.S. patent application number 11/223867 was filed with the patent office on 2006-03-30 for structural post assembly for thermoplastic railing system.
Invention is credited to Larry Stanley.
Application Number | 20060065885 11/223867 |
Document ID | / |
Family ID | 36098013 |
Filed Date | 2006-03-30 |
United States Patent
Application |
20060065885 |
Kind Code |
A1 |
Stanley; Larry |
March 30, 2006 |
Structural post assembly for thermoplastic railing system
Abstract
These and other objects of the present invention are
accomplished by a structural post assembly for a thermoplastic
railing system in which a tubular metal support column is secured
to the substrate upon which thermoplastic railing system is mounted
by means of a base plate, the support column being internally
threaded at its upper end, a slidably rotatable base rail connector
of one piece construction having a segmented cylindrical core
defining an aperture is slidably receivable over the support column
and positioned at the lower end proximate the base plate thereof,
and an adjustable upper rail connector generally cubic in shape
positioned proximate the upper end of the metal support column, the
adjustable upper rail connector and base connector adjustable for
the slidable receipt of a thermoplastic sheath, the thermoplastic
sheath being locked in position by a threaded fastener through the
adjustable upper rail connector and into the internally threaded
aperture of the support column thereby fixing the vertical support
member for the thermoplastic railing system in the correct
horizontal and vertical orientation for geometrical symmetry of the
railing system.
Inventors: |
Stanley; Larry; (Toms River,
NJ) |
Correspondence
Address: |
CLIFFORD G. FRAYNE
136 DRUM POINT RD
SUITE 7A
BRICK
NJ
08723
US
|
Family ID: |
36098013 |
Appl. No.: |
11/223867 |
Filed: |
September 12, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60613046 |
Sep 27, 2004 |
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Current U.S.
Class: |
256/59 |
Current CPC
Class: |
E04F 11/1812 20130101;
E04F 2011/1897 20130101 |
Class at
Publication: |
256/059 |
International
Class: |
E04H 17/14 20060101
E04H017/14 |
Claims
1. A structural support post assembly for thermoplastic railing
systems of the type having a plurality of vertical support posts
having horizontal rails there between said rails having a plurality
of vertical balusters secured thereto, said structural support post
assembly comprising: a base member secured to a substrate, said
base member having a centrally disposed aperture therethrough; a
support pole, cylindrical in cross sectional area, having a lower
end and an upper end, said lower end receivable and securable
within said aperture of said base plate; an adjustable base rail
connector slidably receivable on said support post and positionable
proximate said lower end of said support post, said base rail
connector defined by a segmented cylindrical core having four
outward corner projections in 90 degree flexed relationship to each
adjacent corner projection, each projection defining a corner,
defined by adjacent planar vertical surfaces, the cross section of
said base rail connector defined by said corner projections
equaling the interior cross section of a thermoplastic support post
sleeve slidably engageable over said base rail connector; an
adjustable upper rail connector securable on said upper end of said
support post, said upper rail connector for the slidable receipt
within a thermoplastic support post sleeve, said base rail
connector and said upper rail connector allowing for the correct
orientation and squaring of the thermoplastic support post sleeve
before the connection of horizontal rails of said thermoplastic
railing system.
2. The structural support post assembly for a thermoplastic railing
system in accordance with claim 1 wherein said base rail connector
and said upper rail connector are identical.
3. The structural support post assembly for a thermoplastic railing
system in accordance with claim 2 wherein said base rail connector
and said upper rail connector are each constructed of unitary
construction of molded or extruded polymer and comprises a
segmented cylindrical core defining a central aperture which is
securable on said support post there being four radiating
projections radiating outwardly from said segmented cylindrical
core in 90 degree flexed relationship to each adjacent projection,
each of said radiating projections defining a corner with adjacent
planar vertical surfaces and defining a gap between each adjacent
corner, the segmented cylindrical core and said radiating
projections provide tolerance and flexure for receipt of said
thermoplastic support post sleeve for the orientation and squaring
of the sleeve prior to the attachment of said rails of said railing
system.
4. The structural support post assembly for thermoplastic railing
systems in accordance with claim 3 wherein said upper rail
connector is formed with a vertical slot in a wall of said
segmented cylindrical core, said vertical slot cooperable with an
aperture formed in said support post so as to permit the vertical
slidable adjustment of the upper rail connector and the support
post and to secure the upper rail connector in position by means of
a fastener means cooperable with said slot and said aperture in
said support post.
5. The structural support post assembly for thermoplastic railing
systems in accordance with claim 1 wherein said support pole is
formed with a threaded bore on its upper end, said threaded bore in
axial alignment with said support pole.
6. The structural support post assembly for thermoplastic railing
systems in accordance with claim 5 wherein said upper rail
connector is secured on said upper end of said support pole by
means of a plurality of washers alignable with said segmented
cylindrical core and a threaded fastener means passing through said
plurality of washers and said segmented cylindrical core into said
threaded bore securing said upper rail connector to said support
post.
7. The structural support post assembly for thermoplastic railing
systems in accordance with claim 5 wherein said upper rail
connector comprises a rectangular block member having a
longitudinal slot, said rectangular block member positioned on top
of said support post, and secured thereto by a threaded fastener
passing through said longitudinal slot into said threaded bore,
said rectangular member having at least one dimension equal to the
interior width of said thermoplastic support post sleeve, said
rectangular member adjustable on said support post by means of said
longitudinal slot so as to obtain correct orientation and squaring
of said thermoplastic support post sleeve before connection of said
horizontal rails of said thermoplastic railing system.
8. The structural support post assembly for thermoplastic railing
systems in accordance with claim 5 wherein said upper rail
connector comprises two rectangular block members each having a
longitudinal slot there through, said two rectangular members
secured to said upper end of said support pole by means of a
threaded fastener passing through said longitudinal slots and into
said threaded bore, said two rectangular members being oriented
perpendicular to each other, each of said rectangular members
having a dimension equal to the width of the interior cross section
of said thermoplastic support post sleeve, said two rectangular
members adjustable with respect to each other in order to correctly
orient and square said thermoplastic support post sleeve before
connection of said horizontal rails of said thermoplastic railing
system.
9. A method of installation for a structural support post assembly
for thermoplastic railing systems of the type having a plurality of
vertical support posts having horizontal rails there between, said
horizontal rails having a plurality of vertical balusters secured
thereto, said method of installing said structural support post
assembly comprising: a. securing a base plate member to a
substrate, said base plate member having a centrally disposed
aperture there through; b. positioning a vertical support pole
having a lower end and an upper end, cylindrical in cross section
into said aperture in said base member and securing said vertical
support pole thereto; c. slidably positioning an adjustable base
rail connector onto said support pole and positioning said
adjustable base rail connector proximate said lower end of said
support pole, said adjustable base rail connector defined by a
segmented cylindrical core having four outward corner projections
in 90 degree flex relationship to each adjacent corner projection,
each projection defining a corner, defined by adjacent planar
vertical surfaces, the cross section of said base rail connector
defined by said corner projections and equaling the interior cross
section of a thermoplastic support post sleeve slidably engagable
over said base rail connector; d. positioning an upper rail
connector securable on said upper end of said support pole, said
upper rail connector for slidable receipt within said thermoplastic
support post sleeve; e. slidably positioning said thermoplastic
support post sleeve over said upper rail connector, said lower rail
connector, and said support post; f. adjusting said thermoplastic
support post sleeve utilizing said adjustable base rail connector
and said adjustable upper rail connector to achieve the correct
orientation and squaring of said thermoplastic support post sleeve;
g. securing said upper rail connector to said support post; h.
repeating steps a through g for an adjacent structural support
post; i. securing said horizontal rails between said adjacent
thermoplastic support post sleeves by securing said rails to said
adjustable base rail connector and said adjustable upper rail
connector; and j. repeating steps a through i to complete
construction of said thermoplastic railing system.
Description
RELATED APPLICATIONS
[0001] Applicant claims the benefit of provisional application Ser.
No. 60/613,046, filed Sep. 27, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to thermo plastic rail
systems, and more particularly, to a support post assembly for
thermoplastic rail systems in which the vertical support posts are
square in cross section.
[0004] 2. Description of the Prior Art
[0005] Railing systems serve the purpose of guard rails, hand
rails, grab rails, and in many instances serve as area dividers.
Railings have long been used for a variety of applications such as
stairways, balconies, patios and decks, industrial buildings,
playgrounds and schools, as well as many other wide variety of
uses. These uses are both indoors and outdoors.
[0006] Building codes require the use of high strength material,
such as iron, steel, aluminum wrap or the like to provide
sufficient rigidity and strength to insure adequate safety and
security qualities depending upon the location and purpose of the
railing systems. Thermoplastic railing systems have become popular
due to certain intrinsic qualities. In order to meet building
codes, thermoplastic railing sytems typically include a plurality
of vertical posts which are mounted or secured to a substrate, base
or decking member. These vertical posts are reinforced from within
in order to meet the necessary rigidity and strength
requirements.
[0007] The vertical support posts interconnect with one or more
horizontal rails which in turn may have vertical balusters or other
infill materials such as glass, etc., extending there between.
Usually both of the horizontal rails include a support insert
secured to the vertical support post in order to provide the
necessary rigidity. For an explanation of thermoplastic tubular
support posts which are circular in cross section, see Applicant's
issued U.S. Pat. No. 6,203,233 issued Mar. 20, 2001.
[0008] One particular problem encountered with respect to
thermoplastic support railings occurs when it is desired that the
support railing be square or rectangular in cross section thereby
mimicking a typical wooden railing which one might find on their
back yard deck or patio. Numerous companies originally made their
own plastic sheathing or sleeve members designed to over fit the
wood support post, wooden railings and wooden balusters in order to
protect the underlying wood from the effect of weather and climate.
However, such thermoplastic railing systems must still rely upon
the underlying wooden railing structure for the necessary strength
and rigidity. The industry and market place would prefer a method
or means of strengthening hollow thermoplastic posts without the
need of the underlying wood post.
[0009] Attempts to overcome this problem have resulted in sheathing
the vertical post support and the uppermost horizontal rail member
in which the core would remain wood and the remaining horizontal
rails and balusters would be constructed of tubular rail and
balusters of a square or rectangular hollow cross section. This
solution still requires the installation and sheathing of a
vertical support post at certain incremental distances along the
area to be railed, each of these vertical support posts normally
being dimensions four inches by four inches on each side.
[0010] The necessity of maintaining the underlying four by four
vertical posts makes the installation of a thermoplastic rail
system both expensive and time consuming in that each individual
vertical post must be individually sheathed and can present
difficulties in alignment and the ultimate geometric symmetry of
the railing system.
[0011] The sheathing difficulties and geometric symmetry arise
because not every four by four vertical support post is exactly
dimensioned and since the thermoplastic sheathing is prefabricated,
its inner dimensions, which must conform to the outer dimensions of
the vertical support posts are often incorrect as a result of the
tolerances in fabrication, thus requiring remedial work at the
installation site in order to effectuate a proper installation and
geometric symmetry.
[0012] Applicant has developed a structural post assembly for
utilization with a thermoplastic railing system which is square or
rectangular in cross section which eliminates the need for a solid
vertical wooden support post and provides for a tubular metal
support post secured to the substrate of the railing system, the
tubular metal support post supporting spaced apart tubular
engagement members which are adjustable to the inner diameter of
the thermoplastic railing system and which allow for the
thermoplastic sheathing of the vertical support posts to be
adjusted and secured in situ at the installation site to achieve
proper vertical and horizontal orientation and geometrical symmetry
and to allow the thermoplastic sheathing of the vertical support
post to be secured to the these connectors with the concomitant
intermediate horizontal rails connected and secured to the
thermoplastic sheathing and the vertical balusters secured to the
horizontal rails.
OBJECTS OF THE INVENTION
[0013] An object of the invention is to provide for a novel
structural support post for a thermoplastic railing system in which
the cross section of the thermoplastic railing system is square or
rectangular.
[0014] Another object of the present invention is to provide for a
novel structural post assembly for a thermoplastic rail system
which eliminates the need for a continuous, fixed solid vertical
support post underlying the thermoplastic sheathing of the rail
system.
[0015] A still further object of the present invention is to
provide for a novel support post assembly for a thermoplastic
railing system in which the structural post assembly provides for
internal connectors which allow the installers to adjust the
vertical and horizontal orientation and geometric symmetry at the
installation site with little modification to the underlying
support or thermoplastic sheathing.
[0016] A still further object of the present invention is to
provide for a novel structural post assembly for thermoplastic rail
system in which the inner support connectors for the thermoplastic
sheathing are adjustable to accommodate minor differentials in the
actual internal diameter of the thermoplastic sheathing.
SUMMARY OF THE INVENTION
[0017] These and other objects of the present invention are
accomplished by a structural post assembly for a thermoplastic
railing system in which a tubular metal support column is secured
to the substrate upon which thermoplastic railing system is mounted
by means of a base plate, the support column being internally
threaded at its upper end, a slidably rotatable base rail connector
of one piece construction having a segmented cylindrical core
defining an aperture is slidably receivable over the support column
and positioned at the lower end proximate the base plate thereof,
and an adjustable upper rail connector generally cubic in shape
positioned proximate the upper end of the metal support column, the
adjustable upper rail connector and base connector adjustable for
the slidable receipt of a thermoplastic sheath, the thermoplastic
sheath being locked in position by a threaded fastener through the
adjustable upper rail connector and into the internally threaded
aperture of the support column thereby fixing the vertical support
member for the thermoplastic railing system in the correct
horizontal and vertical orientation for geometrical symmetry of the
railing system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] These and other objects of the present invention will become
apparent, particularly when taken in light of the following
illustrations wherein:
[0019] FIG. 1 is a planar front view of a typical fence or railing
system of the prior art utilizing wooden components;
[0020] FIG. 2 is an exploded view of the support post as sheathed
by the thermoplastic sheathing of the prior art;
[0021] FIG. 3 is an exploded view of a support post of the present
invention;
[0022] FIG. 4 is a top planar view of the base rail connector of
the present invention;
[0023] FIG. 5 is a side planar view of the base rail connector of
the present invention;
[0024] FIG. 6 is a perspective view of the adjustable upper rail
connector of the present invention with the support column;
[0025] FIG. 7 is a top view of a second embodiment of an adjustable
upper rail connector of the present invention;
[0026] FIG. 8 is the exploded view of the support column in
cooperation with the thermoplastic sheathing member;
[0027] FIG. 9 is a side exploded view of a third embodiment of the
structural post assembly of the present invention;
[0028] FIG. 10 is a side exploded view of a fourth embodiment of
the structural post assembly of the present invention; and
[0029] FIG. 11 is a top planar view of the fourth embodiment of the
structural post assembly as illustrated in FIG. 10.
DETAILED DESCRIPTION OF THE INVENTION
[0030] FIG. 1 is a planar front view of a wooden railing assembly
10 incorporating support posts and railings and balusters of either
square or rectangular cross section. The typical railing assembly
10 incorporates a plurality of vertically positioned, spaced apart
support posts 12 generally characterized in the lumber trade as
four by fours. The vertical support posts 12 are secured to the
substrate 14 by means of a base plate 16. Spanning the distance
between adjacent vertical support posts 12 are a plurality of
horizontal rails 18 which are secured to the vertical support posts
12. The horizontal rails 18, in many instances, also support a
plurality of vertical balusters 20.
[0031] Railings of the type illustrated in FIG. 1 are found in many
installations and are commonly used for railings for outdoor decks
or patios and in a variety of commercial settings such as handicap
ramps and the like.
[0032] The wood construction, even if treated, suffers
deterioration from the climate. Periodic treatment of the lumber
would reduce or delay the deterioration, but other solutions have
been explored. One such solution was to sheath the lumber or wood
in a thermoplastic sleeve 22 (See FIG. 2). However, to attempt to
sheath the vertical support posts 12, horizontal railings 18, and
vertical balusters 20, proved to be time consuming and expensive.
The next progression in attempting to solve the problem was to
sheath only the vertical support posts 12 and to use thermoplastic
railing of a square or rectangular cross section as the railings
and balusters for the railing assembly. FIG. 2 illustrates the
manner in which a vertical support post 12 fabricated of wood or
lumber and primarily identified as a four by four would be secured
to the substrate 14 by a base plate 16 and then sheathed in a
thermoplastic sleeve 22 extruded or molded such that its inner
diameter dimensions equaled the outer diameter dimensions of the
vertical support post. Once the thermoplastic sleeve 22 was in
place, a suitable thermoplastic cap 24 would be affixed to the top
of the support post. Railings of a square or rectangular cross
section and formed with a thermoplastic material would then be
installed between adjacent sheathed vertical support posts 12. In
order to comply with relevant building codes, several of the
railings between adjacent sheathed vertical support posts 12 would
have to include a wooden railing member sheathed in a similar
thermoplastic sleeve. Some of the railing members could comprise a
thermoplastic tubular railing of square or rectangular cross
section and be hollow, but all railings could not be installed as
such and meet the building code requirements.
[0033] While the sheathing method provided a solution to the
problem, it raised additional problems in the field in the
installation in that there are many manufacturers of the
thermoplastic tubing or railing. Not all of their inner diameters
were of a tolerance sufficient to accept the underlying vertical
support post four by four in a tight fitting manner. Still further,
when utilizing a solid vertical support post of wood or lumber, of
the four by four variety, it was often difficult with the sheathing
solution to achieve the proper orientation of the vertical support
post such that a geometric symmetry could be achieved in the
resultant railing system.
[0034] FIG. 3 is an exploded view of a support post assembly of the
present invention which permits the installation of a thermoplastic
tubular vertical support post without the need of a continuously
solid vertical wooden support post and which allows for the
corrective orientation of the vertical support post during assembly
and meets all building code requirements for rigidity, strength and
safety. The support post assembly 30 of the present invention
includes a base plate 32 which is securable to the substrate 34
upon which the railing assembly is to be erected. Secured in the
base plate member is the first end 36 of a tubular support post 38
fabricated from a suitable metal. The second end 40 of the support
post 38 is formed with a plug member 42 having an internally
threaded aperture 44 for receipt of a fastening means 46. The
height of the tubular support post 38 is slightly less than the
desired height of the upper railing for the railing assembly.
[0035] Slidably receivable onto vertical tubular support post 38 is
a slidable, rotatable base rail connector 48, preferably of one
piece construction (see FIGS. 4 and 5). Base rail connector 48 is
slidably receivable over the support post 38 and positioned
proximate the lower end 36 of support post 38. The base rail
connector 48 is preferably molded or extruded polymer and is
comprised of a segmented cylindrical core 50 defining a central
aperture 52, and four radiating arms 54 radiating outwardly from
the segmented cylindrical core 50 in 90 degree relationship to each
other, each of said radiating arms 54 defining a corner 56 with
adjacent planar vertical surfaces 58 and 60. The adjacent planar
surfaces 58 and 60 of each defined corner 56 are set apart from the
adjacent planar surfaces of the next adjacent corner by a gap
62.
[0036] The distance from each adjacent corner 56 of the base rail
connector 48 approximates the side distance on a standard wooden
post four by four. The problem with sheathing or encapsulating a
standard wooden four by four support post is the fact that often
times the inner diameter of the thermoplastic sheathing or sleeve
was not of sufficient tolerance to exactly match the outer diameter
dimensions of the vertical wooden support posts. Applicant's base
rail connector 48 with segmented cylindrical core 50 allows for
some tolerance give and flex of radiating arms 54 when sliding the
thermoplastic sleeve over the base rail connector 48 thus allowing
the base rail connector 48 to adapt to different types of
thermoplastic sleeves and the interior tolerance dimensions with
which they were fabricated.
[0037] At the upper end of the tubular support post 38 there would
be positioned an adjustable upper rail connector 70 (See FIG. 6).
Adjustable upper rail connector 70 would be rectangular in shape
and made of suitable materials such as a polymer, the outer
dimensions approximating the inner dimensions of the thermoplastic
sleeve. The adjustable upper rail connector 70 would be formed with
a slot 72 extending through upper rail connector 70 from its upper
surface 74 to its lower surface 76. The width of slot 72 would be
less than the diameter of support post 38 and thus upper rail
connector 70 would not be slidably receivable on support post 38
but would be maintained on top thereof. The slot 72 is designed to
receive a threaded fastener 46 which would pass there through slot
72 and be secured into the internally threaded aperture 44 formed
in the plug member 42 at the upper end 40 of support posts 38. The
diameter of the threaded fastener 46 would be less than the width
of the slot 72.
[0038] In this configuration (See FIG. 8), slidable rotatable base
rail connector 48 would be slidably positioned at the lower end 36
of support post 38. Adjustable upper rail connector 70 would be
positioned on the upper end of support post 38 with threaded
fastener 46 loosely threaded into the internally threaded aperture
44 of plug member 42 in the upper end of support post 38. A
thermoplastic sleeve 22 of four by four configuration would then be
slidably positioned over support post 38 with the lower end of
thermoplastic sleeve 22 being engaged with base rail connector 48
and the upper end of the thermoplastic sleeve 22 being engaged with
the adjustable upper rail connector 70. Any differences in the
tolerances of the thermoplastic sleeve 22 would be adjusted at the
lower end by the base rail connector 48 and its segmented
cylindrical core 50 allowing the radiating arms 54 thereof to shift
slightly in order to accommodate the lower end of the thermoplastic
sleeve. The upper end of the thermoplastic sleeve 22 would be
adjusted by means of upper rail connector 70 by way of sliding
upper rail connector 70 in relationship to the threaded fastener 46
in slot 72. Further, since slot 72 is wider than the diameter of
the threaded fastener 46, there is leeway for the installer to
maneuver upper rail connector 70 in a direction perpendicular to
the orientation of slot 72. When the installer is satisfied that
the thermoplastic sleeve has been positioned over the support post
and is oriented in the correct horizontal and vertical position in
order to achieve geometric symmetry in the railing system, the
installer would then securely tighten threaded fastener 46 into the
internal threaded aperture of the support column 38. Each vertical
support post of a railing system of the type described would be
secured and installed in the manner provided. The thermoplastic
sleeve 22 would be secured to the underlying support by means of a
threaded fastener or the like extending through the thermoplastic
sleeve 22 and into the vertical planar surfaces defined by the
slidably rotatable base connector and into the side surfaces of the
cap connector. The railing systems would then be installed between
adjacent vertical support posts with fasteners engaging the base
rail connector and upper rail connector.
[0039] FIG. 7 is a top view of a second embodiment of the
adjustable upper rail connector identified as 90 for positioning on
the upper end of tubular support member 38. Upper rail connector 90
is of two piece construction comprising two rectangular-shaped
blocks 92 and 94 positioned in overlying 90 degree relationship so
as to form a cross. Each of the rectangular blocks 92 and 94 has a
longitudinal slot 96 and 98 formed there through, the width of the
slot being slightly greater than the width of the fastening means
46. Further, the widths of the slots are less than the diameter of
the support pole 38 and therefore the blocks 92 and 94 which form
the second embodiment of the upper rail connector are positioned
atop the support column 38.
[0040] The linear dimensions of the upper rail connector blocks 92
and 94 approximate the inner dimensions of the side walls of the
thermoplastic sheathing 22. In this configuration, blocks 92 and 94
can be adjusted independently in order to achieve the correct
horizontal and vertical orientation of the thermoplastic sheathing
22 when thermoplastic sheathing 22 is slidably received onto the
support post assembly 30. Once the installer has determined that
the correct vertical, horizontal and geometric orientation has been
achieved, the fastening means 46 would be threaded firmly into the
threaded aperture 44 at the upper end of support column 38. In this
embodiment, as with the first embodiment, a suitable, aesthetic cap
39 member would be secured to the sheath column in order to cover
the fastener means 46.
[0041] In both embodiments of the support post assembly, the
horizontal railings 18 and balusters 20 would be secured to the
sheath spaced apart support post assemblies in conventional
manner.
[0042] FIG. 9 is a side exploded view of a second embodiment of the
structural post assembly 30 of the present invention in which the
adjustable upper rail connector is of similar design to the
slidable, rotatable base rail connector 48 of the first embodiment.
In this embodiment, the upper adjustable upper rail connector 170
is slideably receivable over the support post 38 and positioned
proximate the upper end of support post 38. Upper adjustable upper
rail connector 170 is preferably molded or extruded of polymer and
is substantially identical to base rail connector 48 comprising a
segmented cylindrical core defining a central aperture and four
radiating arms radiating outwardly from the segmented cylindrical
core, in 90 degree relationship to each other, each of said
radiating arms defining a corner with adjacent vertical surfaces.
The adjacent planar surfaces of each defined corner are set apart
from the adjacent planar surfaces of the next adjacent corner by a
gap. The distance from each adjacent corner of upper adjustable cap
connector approximates the side distances of a standard wooden post
4.times.4. Adjustable upper rail connector 170 functions in the
same manner as the rotatable base rail connector 48 of the first
embodiment in allowing the thermoplastic sheathing or sleeve 22 to
slidably engage the upper adjustable upper rail connector 170 and
the base rail connector 48 and upper adjustable upper rail
connector 170 allows for the installer to obtain the correct
vertical or horizontal orientation of the support post.
[0043] Adjustable upper rail connector 170 also has an additional
feature in that one of the walls forming the segmented cylindrical
core is formed with a vertical slot 180. The building codes in
various jurisdictions dictate the required height of a railing
system depending upon its use. In many jurisdictions, the building
codes have specified a residential railing system with a height of
36 inches and in commercial installations require a railing system
with a height of 42 inches. By adjusting the height of adjustable
upper rail connector 170 and the length of slot 180, an installer
can use a standardized length of metal support post 38 for either
commercial or residential installations. The additional height for
a commercial installation is achieved by a threaded fastener 182
and cooperative threaded aperture 184 in the metal support post 38.
Threaded fastener 182 fits into slot 180 on adjustable upper rail
connector 170 and can be tightened down to secure the height at
which adjustable upper rail connector 170 is positioned. If
additional height is required for a commercial installation, the
threaded fastener 180 is loosened, adjustable upper rail connector
170 is slid upwardly to achieve the required height and the
threaded fastener 180 is retightened to secure adjustable upper
rail connector 170 at this increased height position.
[0044] FIG. 10 is a side exploded view of a another embodiment of
the present structure post assembly and FIG. 11 is a top view of
this additional embodiment. In this embodiment, the support post 38
and slidable rotatable base rail connector 48 are installed as
previously described with the other embodiments. In this
embodiment, the adjustable upper rail connector 270 is identical to
the slibable rotatable base rail connector 48 in its structure.
However, in this configuration, adjustable upper rail connector 270
would sit atop support post 38 as opposed to being slidably
received thereon. This is accomplished by positioning a first
washer 190 on the upper surface 40 of support post 38, then
positioning adjustable upper rail connector 270 on this washer with
the central aperture 252 of segmented cylindrical core 250 in
alignment with the aperture in first washer 190 and the threaded
bore in the top of the support post. A second washer 192 and
optional third washer 194 are positioned on top of adjustable upper
rail connector 270 in alignment with the central aperture 252 of
segmented cylindrical core 250. A threaded fastener 46 is then
passed through the apertures of the upper washers 192 and 194, the
central aperture 252 of segmented cylindrical core 250 of
adjustable upper rail connector 270 and the aperture of first
washer 190 and is threaded affixed in the threaded aperture 44 on
the top surface of the support post 38. Threaded fastener 46 is
tightened so as to secure upper adjustable cap connector 270 to
support post 38 is less than the diameter of the apertures of the
washers 190, 192, and 194, and the central aperture 252 of
segmented cylindrical core 250, such that there is some play or
tolerance in the adjustable upper rail connector 270 to allow the
installer to achieve the correct vertical orientation when the
thermoplastic sleeve is secured on the support post assembly. Once
this orientation has been correctly achieved, threaded fastener 46
is further tightened to secure adjustable upper rail connector to
support post 38.
[0045] Washers 192 and 194 are utilized in this particular assembly
because of the unique shape of the upper surface of the adjustable
upper rail connector 270 so there is achielved sufficient contact
surface area with the upper surface to maintain it in position once
the threaded faster 46 is fully threaded downwardly into the
aperture 44 formed in support member 38.
[0046] While the present invention has been described with respect
to the exemplary embodiments thereof, it will be recognized by
those of ordinary skill in the art that many modifications or
changes can be achieved without departing from the spirit and scope
of the invention. Therefore it is manifestly intended that the
invention be limited only by the scope of the claims and the
equivalence thereof.
* * * * *