U.S. patent application number 12/658800 was filed with the patent office on 2011-08-18 for hidden rail fastener connection system.
Invention is credited to Joseph F. Umosella, III.
Application Number | 20110198552 12/658800 |
Document ID | / |
Family ID | 44369000 |
Filed Date | 2011-08-18 |
United States Patent
Application |
20110198552 |
Kind Code |
A1 |
Umosella, III; Joseph F. |
August 18, 2011 |
Hidden rail fastener connection system
Abstract
A hidden rail fastener connection system utilizes open-ended top
and bottom rail supports, each support having a bottom floor and
upstanding side walls. An open-ended channel extends the length of
each side wall and two or more open-ended channels extend the
length of each bottom floor. Specially designed brackets are
secured to the ends of the rail supports. The brackets have a set
of openings aligned with the ends of the channels for the insertion
of fasteners through the openings and into the channels and another
set of openings for the insertion of fasteners into the vertical
structures to which the rail and baluster system is to be attached.
Top and bottom rail members are provided to enclose the rail
supports and cover all fasteners.
Inventors: |
Umosella, III; Joseph F.;
(Hammonton, NJ) |
Family ID: |
44369000 |
Appl. No.: |
12/658800 |
Filed: |
February 16, 2010 |
Current U.S.
Class: |
256/65.08 |
Current CPC
Class: |
E04F 2011/1827 20130101;
E04F 2011/1821 20130101; E04F 11/1817 20130101; E04F 2011/1819
20130101 |
Class at
Publication: |
256/65.08 |
International
Class: |
E04H 17/00 20060101
E04H017/00 |
Claims
1. A hidden fastener rail connection system for attaching rail
members between vertical structures, said system comprising:
elongated top and bottom rail supports each having first and second
open ends and each comprising a bottom floor, the bottom floors
having a plurality of open-ended channels extending the length of
the rail supports, and upstanding side walls, the side walls each
having at least one open-ended channel extending the length of the
rail supports; bracket means for placement over the ends of the
rail supports, said bracket means comprising a first set of opening
means for the insertion of fasteners through the bracket means and
into the channels of the bottom floors and the side walls of the
rail supports, said bracket means further comprising a second set
of opening means for the insertion of fasteners through the bracket
means and into vertical structures; cap means for supporting the
top rail support; a top rail for enclosing the cap means and top
rail support and for covering the fasteners inserted through the
bracket means; and a bottom rail for enclosing the bottom rail
support and for covering the fasteners inserted through the bracket
means.
2. The rail connection system as in claim 1 further comprising
balusters secured between the cap means and the bottom rail.
3. The rail connection system as in claim 1 wherein the bottom
floors of the rail supports comprise two open-ended channels and
each of the side walls comprise one open-ended channel.
4. The rail connection system as in claim 1 wherein the bracket
means comprises a first bracket member located adjacent to the
first open end of each rail support and a second bracket member
located adjacent to the second open end of each rail support.
5. The rail connection system as in claim 3 wherein the bracket
means comprises a first bracket member located adjacent to the
first open end of each rail support and a second bracket member
located adjacent to the second open end of each rail support, each
bracket member having a first set of opening means, said first set
of opening means comprising four openings for the insertion of
fasteners through the bracket members and into the two open-ended
channels of each of the bottom floors and the one open-ended
channel of each of the side walls.
6. The rail connection system as in claim 5 wherein each bracket
member has a second set of opening means, said second set of
opening means comprising two openings for the insertion of
fasteners through the bracket members and into vertical
structures.
7. The rail connection system as in claim 4 wherein the first and
second bracket members are positioned substantially perpendicular
to the ends of the top and bottom rail supports when the fasteners
are inserted through the bracket members into the rail
supports.
8. The rail connection system as in claim 4 wherein the first
bracket members are positioned at a non-right angle to the ends of
the rail supports when the fasteners are inserted through the first
bracket members into the channels of the rail supports, and the
second bracket members are positioned substantially perpendicular
to the ends of the rail supports when the fasteners extend through
the second bracket members.
9. The rail connection system as in claim 8 wherein the second
bracket member comprises a bracket attachment arm and a bracket
support arm extending perpendicularly from said bracket attachment
arm.
10. The rail connection system as in claim 1 wherein the fasteners
through the first set of opening means are oriented 180.degree.
direction in relation to the fasteners through the second set of
opening means.
Description
BACKGROUND OF THE INVENTION
[0001] Railing systems for stairways, decks, porches, and other
structures which employ guardrail type assistance and protection,
usually consist of a number of vertical support newels or columns,
inter-connected by handrails, from which balusters extend. These
components are commonly connected to each other with nails, screws,
rivets, or nuts and bolts. Unfortunately, such fasteners provide
only a relatively small contact surface area between the
components. This results in a less than secure and permanent
connection, one which will often work loose and cause instability
in sections of the railing system. Even after attachment, such
fasteners remain exposed and extend out from the railing
components. This poses a safety risk to those who use the railing
system or pass by it. Aesthetically, exposed fasteners are
unsightly and severely detract from the appearance of the overall
railing system.
[0002] Several rail connection systems are described in the prior
art which seek to address the problem of exposed fasteners. For
instance, the rail connection system disclosed in U.S. Pat. No.
6,874,766 attempts to hide its fasteners, but in so doing
sacrifices the integrity of the railing connection. The system uses
simple end connectors which are positioned on the bottom of a
supporting insert. Such an attachment results in limited lateral
strength and a generally weak connection between components.
SUMMARY OF THE INVENTION
[0003] It is thus the object of the present invention to provide a
hidden rail fastener connection system which overcomes the
limitations and disadvantages of and represents a significant
improvement over prior systems.
[0004] It is an object of the present invention to provide a hidden
rail fastener connection system which provides a strong, stable and
permanent connection between all rail and baluster system
components and the vertical structures to which they are
attached.
[0005] It is another object of the present invention to provide a
hidden rail fastener connection system which uses relatively few
attachment elements to form the fastening connection between rail
and baluster system components.
[0006] It is still another object of the present invention to
provide a hidden rail fastener connection system which connects and
secures rail system components without exposed fasteners which may
present a safety risk.
[0007] It is a further object of the present invention to provide a
hidden rail fastener connection system which permanently connects
and secures rail system components without exposed fasteners, thus
greatly enhance the appearance of the system.
[0008] It is yet another object of the present invention to provide
a hidden rail fastener connection system which is easy and simple
to assemble.
[0009] These and other objects are accomplished by the present
invention, a hidden rail fastener connection system utilizing
open-ended top and bottom rail supports, each support having a
bottom floor and upstanding side walls. An open-ended channel
extends the length of each side wall and two or more open-ended
channels extend the length of each bottom floor. Specially designed
brackets are secured to the ends of the rail supports. The brackets
have a set of openings aligned with the ends of the channels for
the insertion of fasteners through the openings and into the
channels and another set of openings for the insertion of fasteners
into the vertical structures to which the rail and baluster system
is to be attached. Top and bottom rail members are provided to
enclose the rail supports and cover all fasteners.
[0010] Novel features which are considered as characteristic of the
invention are set forth in particular in the appended claims. The
invention, itself, however, both as to its design, construction and
use, together with additional features and advantages thereof, are
best understood upon review of the following detailed description
with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an exploded view of the components of the system
of the present invention.
[0012] FIG. 2 is an exploded view of the top rail components of the
system of the present invention.
[0013] FIG. 3 is an end view of the top rail components of the
system of the present invention as the top rail would be secured to
a newel post.
[0014] FIG. 4 is a perspective view of a support rail component of
the present invention secured between newel posts.
[0015] FIG. 5 is a partial section view of a rail support of the
system of the present invention as installed between newel
posts.
[0016] FIG. 6 is an exploded view of an alternate embodiment of the
top rail components of the system of the present invention.
[0017] FIG. 7 is an elevation view of the rail support shown in
FIG. 6 located for installation between vertical wall
structures.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The hidden fastener rail connection system of the present
invention is provided to secure both the top and bottom rails of a
railing/baluster system. Both top rail support 2 and bottom rail
support 4 comprise an elongated, lightweight extruded member,
preferably, although not limited to, aluminum.
[0019] Using top rail support 2 as an example, as seen in FIG. 2,
the rail support has bottom floor 6 and upstanding sidewalls 8 and
10. Open ended channels 12 and 14 extend along the full length of
bottom floor 6 and open ended channels 16 and 18 extend along the
full length of side walls 8 and 10 respectively. Substantially flat
bracket members 20 comprise first set of openings 22, 24, 26 and
28. Bracket members 20 are configured to be placed adjacent to and
cover both ends of top rail support 2, such that openings 22, 24,
26, and 28 are aligned over the ends of open-ended channels 12, 14,
16, and 18 respectively. With bracket members 20 so positioned,
screw channel fasteners 32, 34, 36, and 38 are inserted into
openings 22, 24, 26, and 28 in both bracket members and then
screwed into channels 12, 14, 16, and 18, to secure the bracket
members to rail support 2.
[0020] Bracket member 20 also comprises openings 23, 25 and 27 to
receive rail fasteners 33, 35 and 37 which are configured to be
oriented 180.degree. in relation to the channel fasteners. (See
FIG. 3). The rail fasteners secure the railing/baluster system to
the newels, columns or walls to which the system is to be
attached.
[0021] Top rail support 2 is supported by and nested within
baluster cap 40, which itself has lateral channels 42 and 44. Top
rail 50 has elongated tab sections 46 and 48. Top rail 50 is
configured to cover both top rail support 2 and cap 40. Tab
sections 46 and 48 are configured to snap into lateral channels 42
and 44, to complete the top rail portion of the rail/baluster
system.
[0022] In like fashion, bottom rail support 4 is enclosed within
bottom rail 60. Bottom rail 60 is configured to straddle, cover,
and attach to bottom rail support 4.
[0023] Installation of the railing/baluster system, by use of the
connection system of the present invention, first comprises
securing balusters 70 to cap 40 and bottom rail 60 via screws or
equivalent fasteners. Top rail support 2 and bottom rail support 4
are then cut to the requisite length. Bracket members 20 are
attached to the ends of top rail support 2 and bottom rail support
4 by inserting and screwing channel fasteners 32, 34, 36, and 38
through bracket openings 22, 24, 26, and 28 and into channels 12,
14, 16 and 18 of the rail supports.
[0024] Rail fasteners 31, 33, and 35 are then inserted into
openings 23, 25 and 27 of bracket members 20 and screwed into newel
posts or columns 62 and 64 or, optionally between two walls or a
wall and newel or column, to secure bottom rail support 4
therebetween. Bottom rail 60, with attached balusters 70 and cap
40, is positioned and secured over bottom rail support 4, thus
covering and hiding all fasteners securing the lower portion of the
railing/baluster system.
[0025] Top rail support 2 is placed into nested position within cap
40. Once again, rail fasteners 31, 33, and 35 are inserted into
openings 23, 25, and 27 of bracket members 20, this time to secure
top rail support 2 between vertical supporting structures, e.g.
newels, columns, or walls. Finally, top rail 50 is positioned and
secured over top rail support 2 and secured to cap 40, thus
covering and hiding all fasteners securing the upper portion of the
railing/baluster system.
[0026] The rail connection system of the present invention can also
be utilized to connect stairway railing/baluster systems. As seen
in FIGS. 6 and 7 showing the top rail support system, upper end 74
of rail support 72 is cut at a diagonal, so as to be parallel to
column, newel or similar vertical structure 200. Bracket member 80
is similar to bracket member 20, except that when placed adjacent
to upper end 74 of rail support 72, it is positioned at a non-right
angle to the rail support. Openings 82, 84, 86, and 88 of bracket
member 80 are configured such that screw channel fasteners 32, 34,
36 and 38 are easily and more readily insertable into channels 12,
14, 16 and 18 of the rail support, for securing the bracket member
to the rail support.
[0027] Stair rail bracket member 90 comprises bracket attachment
arm 92 and bracket support arm 91 extending perpendicular to the
attachment arm. Bracket attachment arm 92 of bracket 90 is
positioned perpendicular and adjacent to lower end 76 of rail
support 72 and fasteners 36 and 38 are inserted through openings 96
and 98 and then into channels 16 and 18 to secure bracket 90 to
rail support 72. Rail support 72 is then placed adjacent to column,
newel or vertical structure 202, such that bracket support arm 91
is against the structure. (FIG. 7). Fasteners 33, 35, and 37 are
next inserted into openings 93, 95, and 97, as previously discussed
with regard to FIG. 3, to secure lower end 76 to vertical structure
202. Rail 100 is then snapped onto cap 94, nested below rail
support 72, to complete the connection.
[0028] Certain novel features and components of this invention are
disclosed in detail in order to make the invention clear in at
least one form thereof. However, it is to be clearly understood
that the invention as disclosed is not necessarily limited to the
exact form and details as disclosed, since it is apparent that
various modifications and changes may be made without departing
from the spirit of the invention.
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