Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: RAILING SYSTEM
FIELD OF THE INVENTION
The present invention relates to railing
systems, and in particular, relates to a connection system
for connecting railings to upright posts.
There are a number of railing systems which
attempt to provide a simple railing for use in association
with decks and porches, and angled railings for stairs.
Many systems use ports provided in plastic extruded
vertical posts, which ports are sized to receive the end of
an extruded railing. These ports are typically provided in
the upright posts at the time of manufacture and many
different posts are required for different configurations.
In other systems the user roughly cuts a port in the post
and an insert is located in the rough opening for finishing
the surface about the port. Systems of this type reduce
the number of specialized posts required, however, the
difficulty in installing the system increases as the user
must determine the position of ports and cut the ports.
It is also known to have fittings with exterior
collars which are applied over the ends of the rails. These
fittings are mechanically secured to the outside of the
post. Other proposed systems use a plug type insert which
is mechanically connected to the outside post and the rail
slides over and locks with the plug member. The various
types of connectors typically require some sort of
mechanical screw type fastening of the components which can
reduce the visual appearance of a product with plug type
connecting systems. It is critical to cut the rails
precisely to achieve the desired visual appearance and as
such, the installation is more difficult. Rails cut off at
an incorrect angle or cut too short, seriously detract from
the appearance of the installed product.
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With these types of systems, the rails and posts
are of an extruded vinyl material and can include metal
reinforcing placed in the length of the railings.
~UNIMARY OF THE INVENTION
A connector for a tubular rail according to the
present invention includes a generally flat base with
passageways therein through which a mechanical fastener can
pass for securing of the connector. An exterior collar
extends from one side of the base and is sized for
receiving the end of a rail in close engagement with the
collar. The collar cooperates with an insert positioned
next to the collar to define a gap therebetween into which
the open end of the tubular rail is inserted. With this
arrangement the rail is trapped and snugly engaged by the
collar and/or the insert.
According to an aspect of the invention the
collar extends outwardly from said base at least one inch.
According to a further aspect of the invention
the gap is of a depth of at least one inch and narrows from
an open end of the collar towards the base.
According to an aspect of the invention the
insert is an inside collar and the gap is defined between
the inside collar and the exterior collar.
According to an aspect of the invention the base
about each passageway includes bosses shaped for engaging
and retaining against rotation the head of a bolt.
According to a further aspect of the invention
the base on a side thereof opposite the exterior collar
includes a small peripheral shoulder extending about the
base for engaging a planar surface to which said collar is
to be secured.
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BRIEF DESCRIPTION OF THE DRAWINGS
- Preferred embodiments of the invention are shown
in the drawings, wherein:
Figure 1 is a partial perspective view of a
railing system;
Figure 2 is a front perspective view showing a
horizontal connector for a rectangular rail;
Figure 3 is a rear perspective view of the
connector of Figure 2;
Figure 4 is a front perspective view of a bottom
connector which faces upwardly for connection with an
angled rail;
Figure 5 is a rear view of the connector of
Figure 4;
Figure 5a is a sectional view of the connector
of Figure 5;
Figure 6 is a front perspective view showing a
connector for a shaped hand rail;
Figure 7 is a rear view of the connector of
Figure 6;
Figures 8 and 9 are front and rear perspective
views of a connector similar to Figure 6, however, the
connector has been angled for receiving a lower end of a
stair rail;
Figures 10 and 11 are front and rear perspective
views of a connector similar to Figures 8 and 9, however,
the connector is for receiving the upper end of a stair
rail;
Figure 12 is a perspective view of a connector
which can be attached to a wooden post, or a vertical wall;
Figures 13 and 14 are perspective views of a
connector similar to Figure 12, but for use with a
rectangular like rail; and
Figure 15 illustrates an adapter commonly used
with either a wooden bottom or a wooden top rail for
convenient insertion of spindles and attachment of the
spindles to the adapter.
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DETAILED DESCRIPTION OF THE PREFERREDEMBODIMENTS
The railing system 2 as shown in Figure 1
includes a horizontal section 1 connected to an angled
section 3 and connected to a further horizontal section 5.
Each of these sections include a handrail 4 connected to a
vertical post 6a or 6b in combination with a bottom rail 8,
extending between posts. A series of spindles 10 connect
the bottom rail and the handrail.
Sections 1 and 5 have the handrail 4 connected
to the vertical post by means of a horizontal handrail
connector 12. The bottom rail 8 is connected to the post
by means of a horizontal bottom rail connector 14. Where
these rails connect to a further post, the same connector
types can be used.
The angled section 3 requires two different
connectors at opposite ends of the hand rail and a
reversible connector 26 for the bottom rail. Handrail 4,
has a downwardly opening angled connector 22 attached to
the upper post 6a and an upwardly opening connector 20
attached to the bottom post 6b. The two connectors are
required as the handrail 4 has distinct top and bottom
surfaces. With respect to the bottom rail 8, its shape is
symmetrical, and as such connectors 26 can be used at both
the top and bottom locations by reversing the orientation
of the connector. Therefore, the transition from the
horizontal section 1 to the angled section 3 to the
horizontal section 4 uses five different types of
connectors secured to posts 6a and 6b. Fortunately, the
eight connectors in total can be secured to whatever face
of the post is necessary. These eight connectors replace
21 different posts that are required for factory based
ported systems.
The eight connectors are used in different
combinations. For example section 1 could be at 90° to the
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angle section 3. In addition, as will be more fully
explained with respect to the drawings of the individual
connectors, these connectors do allow for minor variations
in angle and as such, can accommodate variations in the
rise and run associated with a particular angled section 3.
Details of the various connectors are shown in
Figures 2 through 14. The connector 14 shown in Figures 2
and 3 are used for connecting the rectangular rail of a
horizontal section. The connector 14 includes an outer
collar 36 which defines a slot-like gap 39 between the
outer collar 36 and an inner peripheral insert 38. This
slot 39 is sized to receive the rail and depending upon
tolerance variations will primarily engage the outer collar
36 in a snug fit, or snugly engage the inner peripheral
insert 38. The slot 39 is slight tapered and as such is
wider at the open end for easy insertion of a rail and
narrows toward the bottom wall 42 for engaging the rail.
The back of the connector 14 is shown in Figure 3 and
includes a peripheral shoulder 50 extending thereabout with
the bottom wall 42 being slightly recessed relative to the
back of the connector. The connector has two ports 46
passing through the bottom wall 42 for allowing a
mechanical fastener to pass through a reinforced portion of
the connector and engage the walls of a post.
The bottom wall 42 as shown in Figure 2 includes
two bosses 44 provided about the ports 46 and adapted to
engage the hex heads of a bolt and hold the same against
rotation. This reinforces the bottom wall 42 and
simplifies installation of the connector to a post.
The angled connector 20 for a rectangular rail
is shown in Figures 4 and 5. In this case, the depth of
the connector has been increased to accommodate the angle.
The bottom wall 42 is now disposed at the appropriate angle
of about 30'. In the connector 20 of Figure 5, the bottom
wall 42 is at a similar relationship to the shoulder of the
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connector shown in Figure 3. The slot-like gap 39 does not
run to the approximate depth of the bottom wall 42 at all
- locations, and in fact stops short thereof as shown in the
section of Figure 5a. A varying depth slot 52 is provided
on the back of the connector to reduce the amount of
material and to also assist in the cooling of the part.
The bottom wall 42 is provided with two ports 46 and bosses
44 are provided about the ports for engaging the head of a
bolt. The ports in connector 20 are slightly elongated to
accommodate the angle the connector makes with the post.
Figures 6 and 7 show a connector 14a similar to
the connector of Figures 2 and 3, however, the connector is
shaped for engaging the handrail 4. The connector 20a of
Figures 8 and 9 is the handrail upwardly facing connector
for the angled section and the connector 20b of Figures 10
and 11 is the handrail top connector (downwardly facing)
for the angled section. The connectors of Figures 8 and 10
are different, in that the handrail is not symmetrical, and
therefore, the same connector cannot be used at either end
of the angled section and have the normal top surface of
the handrail up. In some cases the handrail is reversed in
orientation and used as a bottom rail.
One advantage of the various connectors shown in
the Figures is that the connector provides an overlap with
the rails of up to about a one inch. A one inch overlap
has proven sufficient and keeps the connectors relatively
small. Additional overlap, for example, of up to two
inches can be used but the connectors become larger and the
visual appearance of the product may be reduced. The
rails, when inserted in the connectors, either provide a
snug fit with the outer collar, or the inner insert type
plug or both at least near the base of the slot. This
provides a wide tolerance range while still providing a
snug fit and increased strength due to inner and outer
support. The rails are extruded and the tolerance
variation changes occur as a function of the age of the
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extrusion die. Basically, the extrusion die slowly erodes
leading to changes in the dimensions of the final part.
V~Then the effect of the erosion becomes large enough, the
extrusion die is replaced. This arrangement allows for a
larger tolerance variation. The actual connectors are
injection molded, and as such, closer tolerances can be
achieved. Also, with any plastic material, some shrinkage
and/or warpage can occur from time to time. The connector
is designed to engage either the outer or the inner part of
the rail to form a snug connection and this arrangement
simplifies the securing of the rail and the manufacture of
the parts. The connectors, as shown in the drawings, all
use an outer collar and an inner collar or plug type
engagement, with a significant gap therebetween, sized for
receiving the appropriate rail. Obviously, the shape of
the connectors will vary depending upon the desired
exterior shape of the rail. Also, the inner collar can be
replaced with a segmented collar or even angled struts
which provide selective contact with certain areas of the
rail. It is desirable to have the outer collar continuous,
as it provides a finished surface about a cut end of the
rail. In contrast, the inner collar merely has to provide
a snug fit with the interior wall of the rail and is
hidden. It is basically a plug type insert and therefore,
there is additional freedom with respect to the shape
thereof. The segmented collar has a number of advantages
with respect to cooling of the tool, and removal of the
projecting portion of the tool which defines the gap.
Angles struts also have the advantage of simplifying the
tool with respect to forming of the inner plug. It can be
appreciated that the configuration of the inner plug or
collar can vary greatly, as it does not provide a visual
exposed surface in the final product and its function is to
engage the inner part of the rail.
The end user merely has to butt-cut the vinyl
rail in preparation for insertion in a connector. The
connector is appropriately located on the vertical post and
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the location of the ports 46 are marked on the post. The
post can then be drilled to allow a bolt-type fastener to
- pass therethrough. This bolt-type fastener will be exposed
in the interior of the post and access to the fastener for
placing a nut thereon is easily accomplished, as the
connector is close to one end of the post. A ratchet or a
spanner wrench can be used to rotate the nut with the head
of the bolt being held by the boss within the connector.
Figures 12, 13 and 14 show further connectors
60a and 60b, used for fastening of a rail member to a wall.
In this case, the connector is of a much smaller depth and
it has an outer collar 62 about a port 64 through which the
rail 4 can extend. The connector is fastened to the wall
using a conventional fastening arrangement, such as screws.
Each connector has two snap-in cover pieces 80 which hide
the fasteners. The rail generally terminates at the wall
to which the connector is connected.
Figure 15 illustrates a wood to vinyl adapter
90. In some cases, it is desirable to use either a wood
handrail, and/or a wood bottom rail with the top and bottom
rails being connected by plastic or vinyl spindles. The
plastic or vinyl spindles are essentially maintenance free.
For some applications, it is desirable to use a wooden
handrail, as many different styles and configurations are
available and it may also be desirable to use wooden posts.
The selection and style of these products in wood is
extremely varied. The wood to vinyl adapter is also useful
when attaching vinyl spindles to an existing wooden rail.
The converter 90 is mechanically attached to the
bottom surface of the handrail, for example, and a separate
converter is attached to the upper surface of the bottom
rail. This adapter 90 includes spindle ports 92 in the top
surface of the adapter through which the end of a spindle
is inserted. Preferably, the spindle can include locking
tabs which are basically punch-out type tabs in the end of
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the spindle from which a spring detente arrangement for
locking with the adapter. These tabs are cammed inwardly
during insertion of the spindle through the ports 92 and
then snapped beneath the surface and lock with the top
surface of the adapter.
The adapter is an extruded member and can have
any desirable outside configuration. It is desirable to
provide the adapter with a concave bottom surface such that
the bottom edges of the adapter when attached to a bottom
wooden member seat at the edges. The adapter 90 is
mechanically fastened at a number of points along its
length to the handrail or bottom rail, and this fastening
is simplified as it can occur through the ports 92 prior to
insertion of the spindles. The adapter shown in Figure 15
can be used for converting from a wooden handrail to vinyl
spindles which are supported at the lower edge by a vinyl
bottom rail, or perhaps a wooden rail with a similar
adapter provided on the upper surface thereof.
Although various preferred embodiments of the
present invention have been described herein in detail, it
will be appreciated by those skilled in the art, that
variations may be made thereto without departing from the
spirit of the invention or the scope of the appended
claims.
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