Note: Descriptions are shown in the official language in which they were submitted.
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HIDDEN FASTENER GUARD RAIL SYSTEM
FIELD OF THE INVENTION
[0001] This invention relates to guard rail systems. In particular, this
invention relates to a prefabricated guard rail system, components for a guard
rail system and kits of components for a guard rail system that meets building
code requirements.
BACKGROUND
[0002] Guard rails are used around decks, balconies, platforms,
staircases and other elevated structures, to prevent injury and possible death
from failing off of the edge of such structures. Most building codes have
rigid
requirements for guard rails, both in terms of where they are required and
also
prescribing certain construction parameters.
[0003] There is a need for deck and porch railing products that offer the
look and feel of wood, provide a maintenance-free finish, are easily and
quickly installed, have minimal numbers of parts including pieces and
hardware, and which meet building code requirements as above.
[0004] Guard rail systems formed of wood, wood composites, various
vinyl materials, and capped wood composites are available. Guard rail
systems formed of capped wood composites are available in kits for easy
installation whereas guard rail systems formed of wood or wood composites
are fabricated at the job site and assembled using conventional wood
practices, i.e., using screws and nails as fasteners. The fasteners used to
assemble such railing systems are typically exposed, i.e., screw/nail heads
are visible and aesthetically displeasing. Some vinyl guard rail systems such
as PVC (polyvinyl chloride) systems are provided in kits, include pre-drilled
holes and are easily assembled. A shortcoming of most vinyl systems,
however, is that unsightly exposed metal brackets are typically used to secure
the components of the guard rail system together.
[0005] While PVC systems generally offer the advantage of kits,
additional parts and pieces are also required to address installation concerns
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presented by angles and stairs which requires the manufacture of application
specific components. Some PVC systems also use injection molded sleeves
to hide the rail-to-post bracket connection. While the sleeves are generally
effective at masking this connection, the sleeves and screws exposed to
secure the sleeve to the rail detract from the appearance of the rail. Other
PVC systems use routed slot-joint type systems to eliminate exposed
fasteners, yet these components are prone to rattle and require numerous
components with specific routing patterns to address various installation
conditions, e.g. line post, corner post, end post, stair end post, stair thru
post,
and left and right stair to guard rail corners. Moreover, when grasped, hollow
PVC over metal reinforcement rails feel hollow or plastic emphasizing the fact
that the rail system is not formed of wood.
[0006] Capped wood composite guard rail systems offer the advantage
of being provided in kits yet also having the appearance and feel of wood.
Systems having the appearance of wood are typically favored in the guard rail
industry. Current capped wood guard rail systems require metal brackets to
connect the rails to the posts. The metal brackets are typically fastened
below the rail, remaining undesirably visible in the finished assembly and
revealing that the guard rail system is not formed of wood.
[0007] It would therefore be desirable to provide a guard rail system
that has the look and feel of wood, yet is formed of materials that can be
provided in kits for easy assembly, and which further include hidden fasteners
not visible to the exterior.
SUMMARY OF THE INVENTION
[0008] To address these and other needs, and in view of its purposes,
the present invention provides a guard rail system formed of various materials
and which may be pre-cut in kits, including capped wood composite materials
that give the appearance of wood. The system includes hidden fasteners and
brackets that eliminate unsightly screw or nail heads and which undesirably
reveal that the system is not made of wood.
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[0009] According to one aspect of the invention, provided is a guard rail
system that includes an upper rail and a bottom rail affixed to at least two
anchor members and a plurality of balusters affixed to the upper rail and
lower
rail. The upper rail comprises a plurality of cooperating longitudinal members
and includes a longitudinal cavity therein. First fasteners that fasten the
upper
rail to the balusters are not externally visible and the upper rail is affixed
to
each of the anchor members by a bracket disposed completely within the
longitudinal cavity and not externally visible. The anchor member may be a
post or wall or other structure to which a rail may be aftached or anchored.
[0010] In another aspect of the invention, provided is a guard rail
system that includes an upper rail and a bottom rail affixed to at least two
anchor members and a plurality of balusters affixed to the upper rail and
lower
rail. The upper rail comprises a handrail superjacently joined to a top
universal rail with a longitudinal cavity therebetween. First fasteners that
fasten the upper rail to the balusters are not externally visible and the
upper
rail is affixed to each of the anchor members by a bracket disposed
completely within the longitudinal cavity and not externally visible. The top
universal rail has a cross-sectional shape of an upright U and is affixed to
the
balusters.
[0011] In another aspect of the invention, provided is prepared kit for a
guard rail system comprising an upper rail and a lower rail adapted to be
coupled to at least two anchor members, a plurality of balusters adapted to be
coupled to the upper rail and the lower rail, each baluster including a bore
for
receiving a fastener. The upper rail comprises a handrail and a top universal
rail to be joined together, the handrail over the top universal rail, to form
a
longitudinal cavity therebetween. First fasteners that fasten the top
universal
rail to the balusters are not externally visible. Brackets that affix the
upper rail
to each of the anchor members are disposed completely within the
longitudinal cavity and not externally visible.
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BRIEF DESCRIPTION OF THE DRAWING
[0012] The present invention is best understood from the following
detailed description when read in conjunction with the accompanying drawing.
Like numerals denote like features throughout the specification and drawing.
[0013] Figure 1 is a cross-sectional side view of an exemplary guard
rail system of the invention;
[0014] Figure 2 is a perspective view of a portion of the guard rail
system of the invention including the hidden fastener;
[0015] Figure 3 is a perspective view of an exemplary fastener used in
the guard rail system of the invention;
[0016] Figure 4 is a cross-sectional perspective view of an exemplary
guard rail system of the invention; and
[0017] Figures 5 and 6 are cross-sectional end views showing other
exemplary embodiments of the guard rail system of the invention.
DETAILED DESCRIPTION
[0018] The present invention provides a guard rail system formed of
various materials. The components may be formed of vinyl materials such as
PVC, wood composites, or capped wood composites which may include a
white or colored capstock over a wood composite core to produce a painted
look. The finish of the external surfaces used for the upper rail, bottom
rail,
balusters, and post sleeve may be a wood grain finish that provides the look
and feel of wood. The systems may come in kits which are pre-cut and may
include pre-drilled holes for assembly. In one embodiment, any or all of the
balusters, post sleeve, upper and lower rail components may be formed of a
polymer wood composite such as a foamed polymer-fiber composite such as
described in U.S. Patent 6,344,268, issued to the present inventor as one of
multiple inventors. The building materials described in U.S. Patent 6,344,268
include, in one embodiment, a foamed polymer composite building material
consisting of about 35-73 wt. % polyvinyl chloride (PVC) resin, about 27-65
wt. % fiber, a specific gravity of about 1.07 g/cc or less, and including a
porosity of at least 1%. This exemplary foam polymer composite building
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material is capable of having a screw fastener countersunk therein without
pre-drilling. The aforedescribed exemplary building material and the other
building materials disclosed in U.S. Patent 6,344,268 may be used as building
materials of the present invention in various embodiments.
[0019] An aspect of the present invention is that the guard rail system
provides an aesthetically pleasing wood grain finish combined with hidden
fasteners.
[0020] Figure 1 is a cross-sectional side view looking longitudinally
along an exemplary guard rail system. The guard rail system consists of a
plurality of balusters, such as baluster 7, coupled to upper rail 1 and lower
rail
3 which are in turn coupled to a plurality of anchor members such as post 5
having post sleeve 41 and post cap/ring 43. Post sleeve 41 is preferably a
hollow sleeve that is used over a wood 4 x 4 or metal post secured to a deck,
porch, platform, or other patio surface or frame. The aforementioned
components may each be of various different sizes as determined by
application, in other exemplary embodiments. Also, in other exemplary
embodiments, the anchor member may be a wall or other structure fixedly
secured to the ground or another surface and it may include a round cross-
section or other curved surfaces.
[0021] In the exemplary illustrated embodiment, upper rail 1 is formed
of universal rail 13 and top (hand) rail 23 which are joined to produce upper
rail 1 with upper longitudinal cavity 29. In the exemplary illustrated
embodiment, top rail 23 includes longitudinal cavity 49 but as will be shown
in
subsequent figures, this is intended to be exemplary only. Top rail 23 may
optionally include one or more flanges 67 that assist in the alignment or
positioning of top rail 23 on upper universal rail 13. Upper universal rail 13
is
generally U-shaped as assembled and optionally includes at least one flange
17 to aid in aligning baluster 7 to upper rail 1, specifically to upper
universal
rail 13. Lower universal rail 15 also includes optional flange 19 for aligning
baluster 7 to lower universal rail 15. In one embodiment, bottom rail 3 is
formed of universal rail 15 and optional base rail 25 that covers lower
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longitudinal cavity 31 that extends below balusters 7. Both upper and lower
universal rails 13 and 15 include bore 37, indicated by dashed lines, that is
aligned with corresponding bore 39, also indicated by dash lines, formed in
baluster 7. A fastener that secures upper universal rail 13 to baluster 7
extends down from surface 51 and into bores 37 and 39. Such a fastener
may include head 53 which may be countersunk within surface 51 or may rest
above it. In either event, it should be pointed out that when top rail 23 is
in
position over upper universal rail 13, heads 53 of the fasteners used to
couple
upper universal rail 13 to baluster 7, are not externally visible. In other
exemplary embodiments, other fastening means such as various suitable
adhesives may be used to secure upper universal rail 13 to baluster 7. The
bottom portion of upper universal rail 13 may include slots, holes or other
recesses to receive the tops of balusters 7. Balusters 7 may be post-shaped,
as illustrated in Figure 3, or they may take on other shapes such as sheets or
plates that are narrow or lengthy in the longitudinal direction. In various
embodiments, balusters 7 may be glass or polymer plates or sheets that are
4-5" or longer in length, but other baluster shapes and materials may be used
in other exemplary embodiments.
[0022] Top rail 23 may be joined to universal rail 13 by various means.
In one exemplary embodiment, conventional screws or other fasteners may
be used. In one exemplary embodiment, an adhesive such as an epoxy may
be used. In yet another exemplary embodiment, top rail 23 may be snap-fit
into upper universal rail 13 using conventional techniques using slideable
surfaces and cooperating flanges. Top rail 23 may be coupled to upper
universal rail 13 by means of a flange or rib of top rail 23 secured below a
corresponding flange or rib of upper universal rail 13. In yet another
embodiment, top rail 23 may be secured to upper universal rail 13 by a screw
driven upwardly in from the bottom of universal rail 13, and preferably
countersunk within upper universal 13.
[0023] According to the embodiment in which bottom rail 3 is formed of
lower universal rail 15 and optional base rail 25, the same techniques for
joining the base rail, the universal rail, and the balusters, may be used. For
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example, lower universal rail 15 may be fastened to baluster 7 using the same
fastening techniques, and cooperating bores 37 and 39, as described in
conjunction with upper rail 1. Optional crushed block 65 provides support for
the rail system between the anchors.
[0024] The fastener used to couple both upper rail 1 and lower rail 3, to
post 5 or post sleeve 41, is contained within longitudinal cavities 29 and 31,
respectively in the illustrated embodiment of Figure 1. An L-shaped bracket
may advantageously be used. With respect to upper rail 1, the bracket is
therefore not externally visible and with respect to bottom rail 3, the
bracket is
also not externally visible when optional base rail 25 is used. The short face
of generally L-shaped bracket 55 is shown in each of longitudinal cavities 29
and 31.
[0025] Figure 2 is a perspective view showing bracket 55 that includes
long face 57 and short face 59 and is generally L-shaped. Short face 59
includes opening 53 to receive the head of a fastener therein. Long face 57
includes openings such as holes 44. Openings 53 and 44 may optionally be
beveled to accommodate fasteners such as flat head screws. Short face 59 is
designed to be shorter than the corresponding depth of the cavity trench in
which bracket 55 will be disposed and used to couple the rail to the post.
[0026] Figure 3 shows bracket 55 disposed with an upper longitudinal
cavity 29 of upper universal rail 13. It can be seen that fasteners 45 secure
upper universal rail 13 to balusters 7 and according to embodiments in which
the material used to form upper universal rail 13 is a foamed polymer-fiber
composite, fastener 45 may be countersunk within surface 51 without pre-
drilling. In other exemplary embodiments, fasteners 45 may not be
countersunk within upper universal rail 13. Bracket 55 includes holes 44 that
receive fastening members 61 that fasten bracket 55 to upper universal rail 13
and also hole 44 that receives a fastener that additionally fastens upper
universal rail 13 to baluster 7. Short face 59 of bracket 55 includes opening
53. Upper universal rail 13 is coupled to post 5 by lag bolt 63 that is
received
in opening 53 of bracket 55 and extends into post sleeve 41 and post 5. In
other embodiments, lag bolt 63 may extend only into post 5 when there is no
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post sleeve 41, or only into post sleeve 41. Fastening members other than
lag bolt 63 may be used to join bracket 55 to post 5/post sleeve 41 in other
exemplary embodiments. It should be noted that Figure 3 shows the
arrangement prior to the installation of top rail 23 over upper universal rail
13
which closes upper longitudinal cavity 29 and renders the fastening
components shown in Figure 3 in upper longitudinal cavity 29, hidden from the
exterior. The same arrangement may be used in securing lower universal rail
to post 5. Furthermore, each of upper rail 1 and lower rail 3 may be
secured to a plurality of posts 1 with a similar arrangement. If optional base
10 rail 25 is not used, lower longitudinal cavity 31 serves as a trench
extending
upwardly from a bottom surface of lower universal rail 15. Figures 1 and 3
show that bracket 55 does not extend outside the trench and therefore
bracket 55 is not visible from above or laterally, according to embodiments in
which optional base rail 25 is not used.
15 [0027] Figure 4 is a perspective view showing a cut away portion of a
partially assembled guard rail section and illustrates baluster 7, post 5,
bottom
rail 3, and upper rail 401 formed of upper universal rail 13 and top rail 23.
Upper longitudinal cavity 29 and any fastening members that extend within
upper longitudinal cavity 29, are not externally visible. Fastening members
used to join bottom rail 3 to post 5 and baluster 7 do not extend outside
lower
longitudinal cavity 31 and are not visible laterally or from above.
[0028) Figures 5 and 6 each illustrate another exemplary embodiment
of the guard rail system of the invention. In particular, it can be seen that
top
rail 23 takes on different shapes in the illustrated exemplary embodiments of
Figures 1, 5 and 6. For example, top rail 23 may be curved or it may be
substantially flat or planar, or take on a variety of geometric shapes which
may include bevels and edges as desired, for aesthetic purposes. In Figures
5 and 6, top rail 23 does not include cavity 49 included in top rail 23 shown
in
Figure 1 and in Figure 5, top rail 23 includes longitudinal rib 71 that
extends
into upper longitudinal cavity 29. It should be understood that various other
configurations may be used in other exemplary embodiments. Longitudinal
rib 71 may, for example, provide additional surfaces such as the sides of
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longitudinal rib 71 which may fit snugly in upper longitudinal cavity 29, and
to
which adhesives may be applied to join top rail 23 to universal rail 13.
[0029] The preceding merely illustrates the principles of the invention.
It will thus be appreciated that those skilled in the art will be able to
devise
various arrangements which, although not explicitly described or shown
herein, embody the principles of the invention and are included within its
spirit
and scope. Furthermore, all examples and conditional language recited
herein are principally intended expressly to be only for pedagogical purposes
and to aid the reader in understanding the principles of the invention and the
concepts contributed by the inventors to furthering the art, and are to be
construed as being without limitation to such specifically recited examples
and
conditions. Moreover, all statements herein reciting principles, aspects, and
embodiments of the invention, as well as specific examples thereof, are
intended to encompass both structural and functional equivalents thereof.
Additionally, it is intended that such equivalents include both currently
known
equivalents and equivalents developed in the future, i.e., any elements
developed that perform the same function, regardless of structure.
[0030] In the description, relative terms such as "lower," "upper,"
"horizontal," "vertical,", "above," "below," "up," "down," "top" and "bottom"
as
well as derivatives thereof (e.g., "horizontally," "downwardly," "upwardly,"
etc.)
should be construed to refer to the orientation as then described or as shown
in the drawing under discussion. These relative terms are for convenience of
description and do not require that the apparatus be constructed or operated
in a particular orientation. Terms concerning attachments, coupling and the
like, such as "connected" and "interconnected," refer to a relationship
wherein
structures are secured or attached to one another either directly or
indirectly
through intervening structures, as well as both movable or rigid attachments
or relationships, unless expressly described otherwise.
[0031] Although the invention has been described in terms of
exemplary embodiments, it is not limited thereto. Rather, the appended
claims should be construed broadly, to include other variants and
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embodiments of the invention, which may be made by those skilled in the art
without departing from the scope and range of equivalents of the invention.
