U.S. patent application number 16/654689 was filed with the patent office on 2020-02-13 for railing support post with threaded receivers.
The applicant listed for this patent is Joel Duane Herman. Invention is credited to Joel Duane Herman.
Application Number | 20200048928 16/654689 |
Document ID | / |
Family ID | 51653825 |
Filed Date | 2020-02-13 |
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United States Patent
Application |
20200048928 |
Kind Code |
A1 |
Herman; Joel Duane |
February 13, 2020 |
RAILING SUPPORT POST WITH THREADED RECEIVERS
Abstract
A railing support post with threaded holes or receivers for
receiving threaded hardware, such as might be used for tensioned
cable railing. A decorative sleeve or post cover may be used to at
least partially enclose the railing support post. The railing
support post may be manufactured, for example, by providing an
elongated member of a prescribed length, drilling a plurality of
holes spaced along the length of the elongated member, and tapping
the plurality of holes to form a plurality of threaded receivers.
The threaded receivers are configured to receive rail fittings or
other fittings.
Inventors: |
Herman; Joel Duane;
(Thurmont, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Herman; Joel Duane |
Thurmont |
MD |
US |
|
|
Family ID: |
51653825 |
Appl. No.: |
16/654689 |
Filed: |
October 16, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16015554 |
Jun 22, 2018 |
10450774 |
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16654689 |
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14795238 |
Jul 9, 2015 |
10006222 |
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16015554 |
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14308013 |
Jun 18, 2014 |
9126289 |
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14795238 |
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13934566 |
Jul 3, 2013 |
8814145 |
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14308013 |
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61824445 |
May 17, 2013 |
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61668678 |
Jul 6, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04H 17/04 20130101;
B23K 31/02 20130101; E04H 2017/006 20130101; E04F 2011/1821
20130101; B21J 5/066 20130101; E04F 11/1812 20130101; E04F 11/1814
20130101; E04F 11/1859 20130101; E04H 17/10 20130101; E04H 17/24
20130101; E04H 17/12 20130101; E04F 2011/1819 20130101; E04H 17/20
20130101 |
International
Class: |
E04H 17/24 20060101
E04H017/24; B23K 31/02 20060101 B23K031/02; E04F 11/18 20060101
E04F011/18; E04H 17/10 20060101 E04H017/10; E04H 17/20 20060101
E04H017/20; E04H 17/04 20060101 E04H017/04; E04H 17/12 20060101
E04H017/12 |
Claims
1. A railing post apparatus comprising: a support post; one or more
threaded receivers disposed in the support post, the threaded
receivers comprising a plurality of flow-drilled holes in the
support post, the holes spaced along a length of the support post
and one or more of the threaded receivers configured to receive a
cable rail fitting; and a decorative sleeve element configured to
cover two or more sides of the support post, the decorative sleeve
element having one or more pre-drilled holes that are positioned to
be aligned with one or more of the one or more threaded receivers,
the one or more pre-drilled holes positioned to accommodate at
least part of a threaded end portion of one or more cable railing
fittings passed through one or more of the one or more pre-drilled
holes of the decorative sleeve element, where at least a portion of
the support post has an increased thickness as a result of the one
or more threaded receivers being formed by flow-drilling the
support post.
2. The apparatus as claimed in claim 1, where at least one threaded
receiver of the one or more threaded receivers comprises a tapped
hole.
3. The apparatus as claimed in claim 1, further comprising: a
sleeve support member affixed to at least a portion of the support
post.
4. The apparatus as claimed in claim 3, where the sleeve support
member provides a surface of contact for the decorative sleeve
element.
5. The apparatus as claimed in claim 3, where the sleeve support
member has one or more holes thereon.
6. The apparatus as claimed in claim 3, where the sleeve support
member has one or more holes that correspond to holes of the
decorative sleeve element.
7. The apparatus as claimed in claim 3, where the sleeve support
member contacts at least three sides of the support post.
8. The apparatus as claimed in claim 1, where the support post is
located within the interior of the decorative sleeve element.
9. The apparatus as claimed in claim 1, where the decorative sleeve
element covers two or more sides of the support post.
10. The apparatus as claimed in claim 1, where the decorative
sleeve element is poly vinyl chloride.
11. The apparatus as claimed in claim 1, where the decorative
sleeve element is fiberglass.
12. The apparatus as claimed in claim 1, where the decorative
sleeve element is a non-structural material.
13. The apparatus as claimed in claim 1, further comprising: a
threaded fastener; and a spacer adapted to receive the threaded
fastener and the spacer configured to reduce load forces on the
decorative sleeve element.
14. The apparatus as claimed in claim 1, where the support post is
metal.
15. The apparatus as claimed in claim 1, further comprising: a base
member affixed to a portion of the support post.
16. An apparatus comprising: a support post; one or more threaded
receivers disposed proximate to the support post, the threaded
receivers comprising a plurality holes, the holes spaced along a
length of the post; and a decorative sleeve element, the decorative
sleeve element having one or more holes that are positioned to be
aligned with one or more threaded receivers to accommodate one or
more cable medium passed through the one or more holes of the
decorative sleeve element.
17. The apparatus as claimed in claim 16, further comprising: a
base support member coupled to a lower end portion of the support
post configured for location inside the decorative sleeve element
such that a gap is maintained between the decorative sleeve element
and the support post.
18. The apparatus as claimed in claim 16, further comprising a
sleeve support member affixed to a portion of the support post and
adapted to support the decorative sleeve element, when the
decorative sleeve element is affixed to the support post.
19. The apparatus as claimed in claim 18, where the sleeve support
member has one or more holes thereon.
20. The apparatus as claimed in claim 18, where the sleeve support
member contacts at least three sides of the support post.
Description
PRIORITY CLAIM
[0001] This application is a continuation application of U.S.
application Ser. No. 16/015,554 filed on Jun. 22, 2018 entitled
"Railing Support Post with Threaded Receivers" set to issue as U.S.
Pat. No. 10,450,774, which is a continuation application of U.S.
application Ser. No. 14/795,238 filed on Jul. 9, 2015 entitled
"Railing Support Post with Threaded Receivers" now U.S. Pat. No.
10,006,222, which is a continuation of U.S. application Ser. No.
14/308,013 filed on Jun. 18, 2014 entitled "Railing Support Post
with Threaded Receivers" now U.S. Pat. No. 9,126,289, which is a
continuation-in-part application of U.S. application Ser. No.
13/934,566 filed on Jul. 3, 2013 entitled "Railing Support Post
with Threaded Receivers" now U.S. Pat. No. 8,814,145, which claims
the benefit of Provisional Application 61/668,678 filed on Jul. 6,
2012 entitled "Cable Railing System," and Provisional Application
61/824,445 filed on May 17, 2013 entitled "Structural Post with
Threaded Receivers". The subject matter of the aforementioned
applications is hereby incorporated by reference.
BACKGROUND
[0002] The use of decorative post covers and columns has become
increasingly popular in the railing industry. The post covers and
columns are often used to cover unattractive metal fittings and
connectors for cable railing or other types of railings.
Traditionally, a wood post, such as a 4''.times.4'' post, for
example, has been used to transfer railing structural and force
components to the deck or surface on which the inner post is
attached, and a decorative wood, fiberglass, PVC or composite
sleeve is placed over the inner wood post.
[0003] In keeping with such decorative columns or sleeves being
decorative, they often do not provide very much mechanical strength
or integrity to the railing systems in which they are employed,
often being columns or sleeves made of composite materials or
fiberglass. Additionally, cable railings are typically lagged into
wood posts internal to the decorative sleeve or column, in a labor
intensive process requiring the use of expensive hardware and a
structural post abutting the column.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Example embodiments of the present disclosure will be
described below with reference to the included drawings such that
like reference numerals refer to like elements and in which:
[0005] FIG. 1 is a diagrammatic representation of railing support
post, consistent with certain embodiments;
[0006] FIG. 2 is a diagrammatic representation of a decorative
sleeve for a railing support post, consistent with certain
embodiments;
[0007] FIG. 3 is a diagrammatic representation of a decorative
sleeve cap for a railing support post, consistent with certain
embodiments.
[0008] FIG. 4 is a cross-sectional view of an assembly of a railing
support post, a decorative sleeve, and a decorative sleeve cap,
consistent with certain embodiments;
[0009] FIG. 5 is a cross-sectional view of an assembly of a railing
support post, a decorative sleeve, a decorative sleeve cap and an
exemplary rail fitting, consistent with certain embodiments;
[0010] FIGS. 6A and 6B are further cross-sectional views of an
assembly of a railing support post, a decorative sleeve and
exemplary rail fitting, consistent with certain embodiments;
[0011] FIG. 7 is a cross-sectional view of an assembly of a railing
support post, a decorative sleeve, a decorative sleeve cap and an
exemplary rail fitting, consistent with certain embodiments;
[0012] FIG. 8 is a view of a railing assembly utilizing two railing
support posts, consistent with certain embodiments;
[0013] FIG. 9 is a flow chart of a method for manufacturing a
railing support post, consistent with certain embodiments;
[0014] FIG. 10 is a diagrammatic representation of a base support
plate, consistent with certain embodiments;
[0015] FIG. 11 is a view of the section 11-11 shown in FIG. 10;
[0016] FIG. 12 is a diagrammatic representation of a
cross-sectional view of a lower portion of a cable railing support
post assembly, consistent with certain embodiments;
[0017] FIG. 13 is a diagrammatic representation of a lower portion
of a cable railing support assembly viewed from above, consistent
with certain embodiments;
[0018] FIG. 14 is a view of the section 14-14 shown in FIG. 13;
[0019] FIG. 15 is a diagrammatic representation of an upper plate
of a base support bracket of a cable railing support post viewed
from above, consistent with certain embodiments;
[0020] FIG. 16 is a side view of the upper plate shown in FIG. 15;
and
[0021] FIG. 17 is a diagrammatic representation of a lower portion
of a cable railing support post assembly, consistent with certain
embodiments.
DETAILED DESCRIPTION
[0022] For simplicity and clarity of illustration, reference
numerals may be repeated among the figures to indicate
corresponding or analogous elements. Numerous details are set forth
to provide an understanding of the embodiments described herein.
The embodiments may be practiced without these details. In other
instances, well-known methods, procedures, and components have not
been described in detail to avoid obscuring the embodiments
described. The description is not to be considered as limited to
the scope of the embodiments described herein.
[0023] The terms "a" or "an", as used herein, are defined as "one"
or "more than one". The term "plurality", as used herein, is
defined as "two" or "more than two." The term "another", as used
herein, is defined as at least a second or more. The terms
"including" and/or "having", as used herein, are defined as
comprising (i.e., open language). The term "coupled", as used
herein, is defined as connected, although not necessarily directly,
and not necessarily mechanically.
[0024] Reference throughout this document to "one embodiment",
"certain embodiments", "an embodiment", "an example", "an
implementation", "an example" or similar terms means that a
particular feature, structure, or characteristic described in
connection with the embodiment, example or implementation is
included in at least one embodiment, example or implementation of
the present invention. Thus, the appearances of such phrases or in
various places throughout this specification are not necessarily
all referring to the same embodiment, example or implementation.
Furthermore, the particular features, structures, or
characteristics may be combined in any suitable manner in one or
more embodiments, examples or implementations without
limitation.
[0025] The term "or" as used herein is to be interpreted as an
inclusive or meaning any one or any combination. Therefore, "A, B
or C" means "any of the following: A; B; C; A and B; A and C; B and
C; A, B and C". An exception to this definition will occur only
when a combination of elements, functions, steps or acts are in
some way inherently mutually exclusive.
[0026] In accordance with the various embodiments described herein
there is provided a railing support post with pre-threaded,
pre-drilled receivers or inserts, or threaded holes that provides
not only structural support to a decorative sleeve that may be
placed over it, but by having threaded receivers additionally
provides a quick and easy way to connect railing fittings to the
railing support post. An exemplary embodiment is shown in FIG. 1.
The railing support post 100 includes an elongated member 102
having rows of threaded receivers 104, 106 spaced along the length
of the elongated member. In FIG. 1, the elongated member 102 has a
first line of threaded receivers 104 in a first face or side of
elongated member 102 and a second line 106 in a second face or side
of elongated member 102. The other faces of the elongated member
may also include threaded receivers. The threaded receivers are
configured to receive rail fittings suitable for cable railings,
but may be used alone.
[0027] The elongated member 102 has sufficient strength to support
railings, handrails or other fittings, coupled via the threaded
receivers 104, 106, to it. The threaded holes or receivers 104, 106
of the railing support post 100 are spaced in accordance with
spacing of railing to be attached to it and so can support industry
standard railing. The post height may correspond to an industry
standard height, such as 36 inches for residential use and 42
inches for commercial use, for example. Thus, the railing support
post 100 may be a 36 inch residential post or a 42 inch commercial
post. It will be understood that railing support posts of varying
heights may be used without departing from the spirit and scope of
the described embodiments. For example, a shorter railing support
post could be mounted on a knee wall, while a longer railing
support could be mounted with a column or side-mounted on a
facia.
[0028] The railing support post may be made of metal, such as
stainless steel, aluminum, bronze, or other metal material, or
composite material such as material with carbon fibers, etc., with
pre-threaded holes or receivers, thereby allowing cables or other
railings of a railing system to be attached via standard stainless
steel or other known hardware and fitting options to this railing
support post. The threaded receivers 104, 106 of the railing
support post 100 may be evenly spaced threaded holes (such as
vertically to meet code) that are used when cable infill is needed
or desired.
[0029] While the railing support post is illustrated as being
substantially rectangular in shape, it is not so limited and may in
fact be at least partially round or other shapes. Here, the term
"rectangular" is defined to include "square".
[0030] As described below, a separate bracket may be used for the
graspable handrail when desired or needed, as for a 42 inch
commercial application, for example.
[0031] The railing support post may be mounted to a variety of
surfaces, such as decking, stairs, flooring, etc. To facilitate
mounting, a base 108 may be fixed to the lower end of the elongated
member 102. One or more holes 110 in the base may be provided for
fasteners.
[0032] The railing support post 100 also includes a sleeve support
110 coupled to the elongated member 102, the sleeve support 110 is
configured to support a decorative sleeve such that the elongated
member is located in the interior of decorative sleeve. The sleeve
support 110 may include one or more threaded holes 112 to enable
coupling of the post 100 to a decorative sleeve and/or a
handrail.
[0033] When used for guardrail protection or with hand rails
together with hollow composite sleeves, the railing support posts
allow for cables to be attached from any direction. Thus, the
railing support post may be an end post, a corner post, an
intermediate post, etc. The railing support post may then work in
concert with other posts of an overall railing system. For example,
intermediate posts may be used in long sections of railing or
fencing, where cable railing passes straight through the
intermediate posts, or may operate independent of other posts.
Accordingly, threaded receivers may be located on one or more sides
and may be used to receive rail fittings or to allow passage of a
cable rail. In one embodiment, threaded receivers are located on
four sides of the elongated member.
[0034] FIG. 2 is a diagrammatic representation of a decorative
sleeve or post cover 200 configured to at least partially enclose a
railing support post. The decorative sleeve 200 may be constructed
of a light-weight, non-structural material, such as PVC or
fiberglass. One or more holes 202 may be provided to allow railing
fittings to pass through the sleeve to threaded receivers in the
interior railing support post. Additional holes 204 may be provided
to enable coupling of the decorative sleeve 200 to a sleeve support
of the railing support post.
[0035] The decorative sleeve may be provided without holes 202 and
204. The holes may be added, as needed, during installation of a
railing assembly. To facilitate installation, a drill-hole template
may be provided to indicate where holes may be drilled in the
decorative sleeve so as to align with the threaded receivers in the
elongated member. The template, support post, decorative sleeve and
other components may be provided as a kit.
[0036] In an exemplary embodiment, the elongated member has a
substantially square cross-section, with outside width
approximately 2 inches. In a further embodiment the outside width
is in the range 1-3 inches. Larger or smaller widths may be used
without departing from the present disclosure.
[0037] The elongated member may have a solid, hollow, U-shaped,
L-shaped, T-shaped, H-shaped, I-shaped, round, rectangular or other
cross-section. The elongated member may be constructed of a
thin-walled material, such as 1/8'', 3/16'', 1/4'' or 5/16'' metal.
Other materials and material thicknesses may be used, provided the
railing support post has sufficient strength to support one or more
railings.
[0038] In an exemplary embodiment, the decorative sleeve has a
substantially square cross-section, with outside width
approximately 5 inches. In a further embodiment the outside width
is in the range 4-6 inches. Larger or smaller widths may be used
without departing from the present disclosure.
[0039] The decorative sleeve 200 is sized to pass over the
elongated member and the base support bracket of the railing
support post.
[0040] In an exemplary embodiment, the base support bracket of the
railing support post is substantially square, with width
approximately 4.2 inches. In a further embodiment the outside width
is in the range 2-7 inches. Larger or smaller widths may be used
without departing from the present disclosure.
[0041] FIG. 3 is a diagrammatic representation of a decorative
sleeve cap 300 configured to be located on top of a decorative
sleeve. In a further embodiment, the decorative cap 300 is integral
with the decorative sleeve. A variety of cap styles will be
apparent to those of ordinary skill in the art. In some
embodiments, the cap is integrated with the decorative sleeve.
[0042] FIG. 4 is a vertical, cross-sectional view through an
assembly of a railing support post 102, a decorative sleeve 200 and
a decorative sleeve cap 300, in accordance with one or more
embodiments. Various embodiments of threaded receivers 106 are
shown by way of explanation. In practice, a railing support post
may contain a single type of threaded receiver. Receiver 106a
comprises a front-plate, with both the front-plate and elongated
member 102 being threaded. Receiver 106b comprises a simple
threaded hole in the elongated member 102. Receiver 106c comprises
a threaded insert. Receiver 106d comprises a threaded flow-drilled
hole. Receiver 106e comprises a threaded front-plate. Other types
of threaded receivers will be apparent to those of ordinary skill
in the art.
[0043] In the example embodiment shown, the railing support post is
coupled to a surface 402 using fasteners 404. Various types of
fasteners may be used.
[0044] Railing fittings that are configured to be placed in tension
may be passed through holes 202 in the decorative support sleeve
200 and screwed into threaded receivers 106 of the railing support
post. Fittings that require a mating surface may be coupled via a
spacer, such as hollow spacer 406 that rests against the elongated
member 102. Spacer 406 provides an external mating surface and is
sized to span the gap between the elongated member 102 and the
exterior of the decorative sleeve 200, passing through a hole in
the decorative sleeve 200. The spacer 406 is adapted to protect the
decorative sleeve from compressive loads when a rail fitting is
coupled to the threaded receiver of the elongated member. Spacer
406 may also be used, for example, when a cable rail is angled
diagonally up or down, as for a step or stair railing to prevent
loading of the decorative sleeve.
[0045] The decorative sleeve 200 may be attached to the sleeve
support 112 of the railing support post via a fastener 408.
[0046] Together, the decorative sleeve 200 and support cap 300
enclose the railing support post 300.
[0047] The railing support post allows for the tensioning of cables
to be transferred to the surface of the railing support post inside
a decorative sleeve, thereby allowing the decorative sleeve or
shell to become lighter and more decorative.
[0048] A top handrail or guard rail may be bolted directly to the
railing support post using the threaded holes in the top sleeve
support 112. In one example embodiment, the sleeve support 112
comprises square tubing, such as 1 inch square, for example. This
will accommodate all angles that a standard stair arrangement might
use. The sleeve supports 112 may be attached at one or more
positions on the elongated member. The sleeve support may be
pre-attached, by welding or bonding for example, or may be attached
using fasteners. The sleeve support is sized to accommodate the
decorative sleeve to be used.
[0049] A grab-rail 410 may be attached to the railing support post
via spacer 406 and bracket 412. A threaded fastener 414 passes
through the spacer 406 and the threaded portion 416 of the fastener
screws into a threaded receiver of the elongated member 102. An
additional hollow spacing element 418 may be used to provide a
stand-off. Optionally, elements 406 and 418 may be combined as a
single spacer that enables the bracket 412 to be coupled to the
elongated member 102 without loading the decorative sleeve 200.
[0050] In a further embodiment, the sleeve support is integrated
with the decorative sleeve. In a still further embodiment, the
decorative cap is integrated with the decorative sleeve. In a still
further embodiment, the sleeve support, the decorative sleeve and
the decorative cap are integrated. For example, the sleeve support,
the decorative sleeve and the decorative cap may be molded as a
single plastic part.
[0051] FIG. 5 is a vertical, cross-sectional view through an
assembly of a railing support post 102, a decorative sleeve 200, a
decorative sleeve cap 300 and exemplary railing fittings, in
accordance with various embodiments. A horizontal guardrail 502 may
be coupled to the sleeve support 112. Mechanical loads placed on
the guardrail 502 are carried by the elongated member 102 of the
railing support post rather than by the decorative sleeve 200. A
grab-rail 410 may be coupled to the elongated member by a support
bracket 506. In the example shown, the support bracket 506 has a
flange that is mounted to the elongated member 102 using two
threaded receivers. In one example embodiment, the attachment point
of the bracket 506 may be located approximately one fourth of the
way between the flange holes and/or may be invertible to allow for
a variety of handrail heights. By way of illustration, the
grab-rail 410 and support bracket 506 are depicted as being coupled
to the right of the elongated member 102. However, the grab-rail
410 and support bracket 506 may be coupled to the front or back
face of the elongated member 102 so as to provide a grab-rail 410
running parallel to the cable sections 508.
[0052] Cable sections 508 may be attached to the threaded receivers
106 of the railing support post using fittings 510. The fittings
510 have a threaded section 512 that may be screwed in a threaded
receiver to hold the cable section 508 in tension. The fittings 510
pass through the decorative sleeve 200 but are not supported by it.
Thus, the decorative sleeve 200 may be constructed of various light
weight decorative materials.
[0053] The fittings 510 may have two threaded ends 512. One
threaded end of a fitting may have left-hand thread and the other
end a right-hand thread to facilitate tensioning. One threaded end
allows coupling to a cable rail while the other threaded end 512
allows coupling to the elongated member 102. Tension in the cable
section 508 may be adjusted by rotating the body of the fitting.
Rotation may be facilitated by a hexagonal, square, or flattened
section of the fitting.
[0054] FIG. 6A is a partial, cross-sectional view through an
assembly of a railing support post 102, a decorative sleeve 200 and
exemplary railing fittings, in accordance with various embodiments.
A cable section 508 is passes through a flow-drilled hole 106 in
the decorative sleeve or post cover 200 and is coupled to the
elongated member 102. Insert 602 may be screwed on the threaded
portion 512 of the rail fitting 510 and functions to protect the
decorative sleeve 200 surround the fitting and to enhance
appearance of the assembled railing. The fitting may be provided
with a hexagonal, square, or flattened section 604 to facilitate
tensioning of the cable section 508. Other types of fittings will
be apparent to those of ordinary skill in the art.
[0055] In FIG. 6A, the wall thickness of decorative sleeve or post
cover 200 is depicted as being thinner than the wall thickness of
the elongated member 102. However, other wall thicknesses may be
used without departing from the present disclosure. For example,
FIG. 6B is a partial, cross-sectional view through an assembly of a
railing support post 102, a decorative sleeve 200 and exemplary
railing fittings, in accordance with an embodiment. In this
embodiment, the wall thickness of decorative sleeve or post cover
200 is depicted thicker than the wall thickness of the elongated
member 102.
[0056] FIG. 7 is a cross-sectional view of an assembly of a railing
support post 100, a decorative sleeve 200, a decorative sleeve cap
300 and exemplary rail fittings 510, consistent with certain
embodiments. The base support bracket 108 is fastened to the
surface 402 using fasteners 404. The decorative sleeve 200 is
placed over the elongated member 102 of the railing support post
100, and decorative cap 300 is installed. Guard rails 502 are
attached to the sleeve support 112 of the railing support post
using fasteners 408. In the embodiment shown, the cable rails 508
extend through threaded receivers 106 the elongated member 102 and
holes 202 in the decorative sleeve 200 to emerge on the opposite
side of the decorative sleeve. In this way, the cable rails 508 can
continue through one or more railing support posts to extend the
rail. In addition, a variety of rail fittings may be used. The rail
fitting may be configured to facilitate screwing the fitting into a
threaded receiver to apply tension to the attached cable rail.
[0057] In the embodiment illustrated in FIG. 7, the decorative cap
300 is incorporated with the decorative sleeve 200. In addition,
the elongated member may be embedded in the decorative cap to
provide the sleeve support.
[0058] The railing support post may also be used in conjunction
with many kinds of lighting fixtures, should the need arise.
[0059] A wide variety of materials may be used for each of the
various components, fixtures, and elements described herein,
including aluminum, stainless steel, steel, wood, cast aluminum,
brass, bronze, aluminum bronze, nickel aluminum bronze, nick
bronze, carbon fiber, and plastic, as well as cast, extruded or
extrusion parts.
[0060] FIG. 8 is a view of a railing assembly using two railing
support posts, consistent with certain embodiments. The first
railing support post 100a is located in a decorative sleeve 200a
that take the form of a pillar that extends from floor 402 to
ceiling 802. A cable 804 may be stretched between the floor 402 and
the ceiling 802 to help support the railing support post 100a and
help meet hurricane "lift-off" requirements. A second railing
support post 100b is fastened to the floor 402. The railing support
post 100b may be fastened using a base support bracket, a cable
fastened to the floor, or a combination thereof. The railing
support post 100b is covered by a decorative sleeve 200b and a
decorative cap 300. A guard rail 502 is coupled to the first
railing support post 100a via bracket 506 and to the second railing
support post via sleeve support 112. A number of cable rails 508
are stretched between the two railing support posts. The cable
rails 508 are coupled to the railing support posts using fittings
510 that screw into threaded receivers of the railing support
posts. The fittings 510 enable the tension in the cable rails to be
adjusted. The tension is supported by the railing support posts
100a and 100b so that the decorative sleeves 200a and 200b can be
constructed of light-weight decorative materials. The height of the
guard rail 502 and the spacing between cable rails 508 may be
selected to meet building codes. The cable rail spacing may be
predetermined, so that the threaded receivers can be fabricated
when the support post is manufactured, thereby minimizing the
installation time of a railing assembly.
[0061] In an exemplary embodiment, the threaded receivers are
evenly spaced at approximately 3.09 inch spacing. However, other
spacing may be used.
[0062] FIG. 9 is a flow chart 900 of a method for manufacturing a
rail support post, in accordance with certain embodiments of the
disclosure. Following start block 902, an elongated member of a
desired length is provided. The desired length may correspond to a
standard length specified in a building codes, or may be a custom
length. At block 906 a plurality of holes are drilled in the
elongated member. The holes are spaced in a row along the length of
the elongated member. Rows of holes may be place on some or all
sides of the elongated member. The elongated member may have a
hollow or solid cross-section. When a hollow or angular
cross-section is used, the holes may be drilled using
flow-drilling, so as to increase the thickness of the elongated
member in the vicinity of the hole and provide an increased thread
length. This approach allows thinner materials to be used without
the use of front- or back-plates to increase the thread length.
However, other methods may be used to create the holes, such as
conventional drilling, laser cutting, punching, etc. The holes are
tapped at block 908 to form a plurality of threaded receivers. The
threaded receivers are configured to receiver rail fittings due
use, and may be fabricated by other means.
[0063] At block 910, a base support bracket is prepared. In one
embodiment, the base support bracket is made by cutting the bracket
from a sheet of metal and drilling or cutting holes in it to enable
it to be attached to a mounting surface. Optionally, a lower sleeve
support may be incorporated. In one embodiment this may be done by
machining one or more steps in the block to form one or more raised
platforms sized to fit inside a hollow decorative sleeve placed
over the post. In a further embodiment, one or more upper plates
may be added in a stack to form one or more raised platforms, again
sized to fit inside a hollow decorative sleeve placed over the
post. The edges or corners of an upper plate may be bent upwards to
guide the plate(s) inside the decorative sleeve.
[0064] At block 912, a base support bracket is attached to an end
of the elongated member, the base support bracket being configured
to enable the elongated member to be fastened to a surface when in
use. The base support bracket may be attached by welding or
bonding, for example.
[0065] At block 914, a sleeve support is attached to the elongated
member. The sleeve is configured to provide support for a
decorative sleeve that, at least partially, encloses the elongated
member in use. The sleeve support may be attached by welding or
bonding, for example. The manufacture terminates at block 916.
[0066] Additional manufacturing steps may be performed. For
example, if the support post is constructed of stainless steel, a
passivation step may be included. For other materials, an
anti-corrosion coating may be applied, for example.
[0067] As described above a cable rail support post may be produced
by a process comprising: providing an elongated member having one
or more walls, flow-drilling a number of holes in at least one
walls of the elongated member, the holes spaced along a length of
the elongated member. Flow-drilling a hole increases the thickness
of the wall in the vicinity of the hole. The flow-drilled holes are
tapped to produce multiple threaded receivers spaced along a length
of the elongated member, that can be used to receive cable rail
fittings. A base support bracket is attached to a lower end portion
of the elongated member, the base support bracket configured to
enable the cable rail support post to be fastened to a surface. A
sleeve support may be joined to the elongated member, at the upper
or lower end portion, for example, the sleeve support adapted to
support a decorative sleeve that at least partially encloses the
elongated member. In one embodiment, the base support bracket is
welded to the first end portion of the elongated member.
[0068] The base support bracket may have one or more raised
platforms, each raised platform sized to match an interior
dimension of a hollow decorative sleeve. The platforms may be
produced by machining or casting one or more steps may be machined
or cast around a perimeter of the base support bracket. In a
further embodiment, two or more plate elements of different sizes
are joined in a stack to produce the base support element. The
plates may be cut from sheet metal.
[0069] In one embodiment, the base support bracket comprises a
lower plate and an upper plate. The lower plate is joined to and
supports the lower end portion of the elongated member. The lower
plate has a first set of holes to enable the cable rail support
post to be attached to a surface. The upper plate is sized to match
an interior dimension of a hollow decorative sleeve, and is
mountable on the lower plate such that a second set of holes in the
upper plate aligns with first set of holes of the lower plate. The
lower plate is adapted to support a decorative sleeve passed over
the elongated member.
[0070] Optionally, at least one side portion of the upper plate is
bent upwards to facilitate alignment of a hollow decorative sleeve
around the upper plate.
[0071] The lower plate may be cut from sheet metal of a first
thickness, while the upper plate is cut from sheet metal of a
second thickness, the second thickness less being than the first
thickness.
[0072] A lateral dimension of the base support bracket may be
approximately 4'' and a thickness of the base support bracket may
be greater than 5/16'' in certain embodiments. The base support
bracket may be approximately square, or another shape.
[0073] In one embodiment, the elongated member is made of metal and
has a wall thickness of between 1/16'' and 3/8''.
[0074] The cable rail support post may be manufactured by providing
an elongated member having one or more walls, providing a base
support bracket, and forming a set of threaded receivers spaced
along a length of the elongated member. A threaded receiver may be
produced by flow-drilling a hole in the elongated member, where the
flow drilling increases the thickness of the wall in the vicinity
of the hole, and tapping the flow-drilling hole. Two or more
mounting holes are made in the base support bracket and the base
support bracket is welded to an end of the elongated member. The
threaded receivers are configured to receive rail fittings.
[0075] The base support bracket and the mounting holes may be cut
from a sheet of metal having a thickness between 1/4'' and 3/4'',
and one or more steps may be machined around a perimeter of a plate
element to provide one or more raised platforms, each raised
platform being sized to match an interior dimension of a hollow
decorative sleeve. Alternatively, the base support bracket may be
made by casting a plate element having one or more steps around its
perimeter, each raised platform being sized to match an interior
dimension of a hollow decorative sleeve.
[0076] In a further embodiment, the base support bracket is made by
joining two or more plate element of different sizes in a stack to
provide one or more raised platforms, each raised platform being
sized to match an interior dimension of a hollow decorative
sleeve.
[0077] FIG. 10 is a diagrammatic representation of a base support
plate, consistent with certain embodiments. Referring to FIG. 10,
the base support bracket 108 has a number of holes 110 that enable
the bracket to be attached to a mounting surface, such as deck or
floor, using fixings such bolts or screws that pass through the
holes. An additional hole 1002 may be included to allow for
drainage of water from the interior of the post. A number of steps
1004 are provided such that the bracket comprises a number of
raised platforms of different sizes. The dimensions of the
platforms, indicated by the arrows 1006 for example, are selected
to correspond to or be just less than the interior dimension of a
hollow decorative sleeve placed over the post. The decorative
sleeve is discussed in more detail above. In one embodiments, a
single raised platform may is used. In a further embodiment, a
series of platforms are used to accommodate decorative sleeves with
different internal dimensions.
[0078] In one embodiment, the base 108 is approximately 4'' square,
the upper raised platform is approximately 3.66'' square, the
middle raised platform is approximately 3.77'' square and the lower
raised platform is approximately 3.83'' square. However, it will be
apparent to those of ordinary skill in the art that other
dimensions may be used.
[0079] In FIG. 10, the raised platforms are substantially square.
However, other shapes may be used, such as elliptical, circular,
triangular, etc.
[0080] FIG. 11 is a view of the section 11-11 shown in FIG. 10. The
base support bracket has a number of steps 1004 that form a number
of raised platforms. The base support bracket may be produced by
machining the steps in a metal plate or by casting. Machining may
be performed by a known process, such as turning, milling, planing,
shaping, broaching, grinding, ultrasonic machining, chemical
machining, electrical discharge machining, electrochemical
machining, high-energy beam machining, etc.
[0081] In one embodiment, the height of the steps is approximately
1/16''. In a further embodiment the height of the steps is greater
than 1/16''.
[0082] FIG. 12 is a diagrammatic representation of cross-section of
a lower portion of a cable railing support post assembly,
consistent with certain embodiments. The assembly includes the
elongated member 102 and the base support bracket 108 that form the
cable rail support post. The base support bracket is attached to
surface 402 using fixing 404 that passes through a hole 110 in the
bracket. In practice, fixings 402 would be placed in two or more of
the holes 110. The assembly also includes a hollow decorative
sleeve 200 that passes over the elongated member 102 and rests on a
step 1104 of the base support bracket 108. In the example shown,
the sleeve rests on the lower step. Sleeves with smaller internal
dimension 1204 might rest on a different step. A decorative collar
1206 may be placed around the base of the support post and sleeve
to hide the edges of the base support bracket 108 and the lower end
of the sleeve 200. In this example, hole 1208 is aligned with hole
1002 to provide drainage. In this example, the raised platforms are
integral to (part of) the base support bracket and provided a lower
support for the decorative sleeve 200.
[0083] FIG. 13 is a diagrammatic representation of a lower portion
of a cable railing support assembly viewed from above, consistent
with certain embodiments. In this embodiment, the base support 108
includes a lower plate 1302 that is attached to the elongated
member 102, and an upper plate 1304 that provides a lower support
for the decorative sleeve. The lower plate 1302 has sufficient
strength to provide structural support for the post. In one
embodiment, the plate is approximately 3/8'' thick. In further
embodiments, the plate thickness is as little as 1/4'', but may be
thicker, such as approximately 1/2'', 3/4'' or 1''. The thickness
may be selected according to the material of the base support
bracket and/or the height of the post.
[0084] The upper plate 1304 may have a central cut-out 1308 with
sufficient width 1306 to enable it to be positioned before or after
the elongated member 102 is joined to the base support bracket 108.
The upper plate 1304 also has a number of holes 1301 that align
with corresponding holes in the lower plate 1302. The dimension
1006 of the upper plate is selected to mate with an internal
dimension of a decorative sleeve. Thus, in use, the upper plate
prevents lateral motion of the decorative sleeve. The upper plate
may be joined to the lower plate during manufacture, or may be
supplied separately and held in place by the base support bracket
fixings. More than one upper plate may be stacked to allow for
decorative sleeves of different internal dimensions.
[0085] FIG. 14 is a view of the section 14-14 shown in FIG. 13.
This view illustrates how the combination of the lower plate 1302
and the upper plate 1304 form a step 1004 and a raised platform
1304. Hole 1002 is open to the interior of the elongated member 102
to provide drainage.
[0086] FIG. 15 is a diagrammatic representation of a further upper
plate of a base support bracket of a cable railing support post
viewed from above, consistent with certain embodiments. In this
embodiment, the upper plate 1304 is cut from a sheet of metal.
Holes 1310 and central cut-out 1308 may be cut during the same
process step. The corners 1502 of the plate are bent upwards to
positions 1502' at approximately 90.degree. to the plate. The
cutting and bending may be performed in a single stamping process
or as separate processes. In one embodiment, perforations are cut
along the bend lines to facilitate bending during manufacture or
bending at a later time, such as the time of installation.
[0087] FIG. 16 is a side view of the upper plate shown in FIG. 15.
This view shows the corner 1502' at approximately 90.degree. to the
lower portion of the plate. The corners function as guides for a
decorative sleeve as it is passed over the support post and prevent
lateral motion of the decorative sleeve once it is positioned.
[0088] FIG. 17 is a diagrammatic representation of a lower portion
of a cable railing support post assembly, consistent with certain
embodiments. As described above, the corners 1502' function as
guides for a decorative sleeve 200 as it is passed over the support
post 102 and prevent lateral motion of the decorative sleeve 200
once it is positioned. The material of the upper plate 1304 may be
selected to allow for manual flexing of the corners 1304 to
accommodate manufacturing variability in the decorative sleeves.
Fixings 404 pass through aligned holes 1310 in the upper plate and
110 in the lower plate and server to support the post and join the
upper plate 1304 to the lower plate of base 108.
[0089] In accordance with various embodiments presented herein, a
cable rail support post is produced by a process, the process
comprising: providing an elongated member having one or more walls;
flow-drilling a plurality of holes in at least one wall of the
elongated member, the holes spaced along a length of the elongated
member, where the flow-drilling of a hole increases the thickness
of the wall in the vicinity of the hole; tapping the plurality of
flow-drilled holes to produce a plurality of threaded receivers
spaced along a length of the elongated member, the plurality of
threaded receivers configured to receive cable rail fittings; and
joining a base support bracket to a lower end portion of the
elongated member, the base support bracket configured to enable the
cable rail support post to be fastened to a surface.
[0090] Further in accordance with embodiments described herein a
method of manufacturing a cable rail support post is provided, the
method comprising: providing an elongated member having one or more
walls; providing a base support bracket; forming a plurality of
threaded receivers spaced along a length of the elongated member, a
threaded receiver of the plurality of threaded receivers produced
by: flow-drilling a hole in a wall of the elongated member, where
the flow drilling increases the thickness of the wall in the
vicinity of the hole; and tapping the flow-drilling hole, forming a
plurality of mounting holes in the base support bracket; and
welding a base support bracket to an end of the elongated member,
where the threaded receivers are configured to receive rail
fittings.
[0091] Also provided is a cable rail support post in accordance
with the various embodiments described herein, the cable rail
support post comprising: an elongated member having one or more
walls; a plurality of thread receivers comprising tapped holes in
at least one wall of the elongated member, the holes spaced along a
length of the elongated member, the plurality of threaded receivers
configured to receive cable rail fittings; and a base support
bracket coupled to a lower end portion of the elongated member, the
base support bracket configured to enable the cable rail support
post to be fastened to a surface and further configured to support
a lower portion of a hollow decorative sleeve placed over the
support post, the base support post comprising one or more raised
platforms, a raised platform of the one or more raised platforms
sized to engage an interior dimension of the lower portion of the
hollow decorative sleeve.
[0092] The implementations of the present disclosure, described
above, are intended to be examples only. Those of skill in the art
can effect alterations, modifications and variations to the
particular example embodiments herein without departing from the
intended scope of the present disclosure. Moreover, selected
features from one or more of the above-described example
embodiments can be combined to create alternative example
embodiments not explicitly described herein.
[0093] The present disclosure may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the disclosure is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes that come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *