Note: Descriptions are shown in the official language in which they were submitted.
CA 02894334 2015-06-16
RAILING SUPPORT POST WITH THREADED
RECEIVERS
BACKGROUND
[0001] 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" x 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.
[0002] In keepin 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
[0003] 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:
[0004] FIG. 1 is a diagrammatic representation of railing support post,
consistent with certain embodiments;
[0005] FIG. 2 is a diagrammatic representation of a decorative sleeve for a
railing support post, consistent with certain embodiments;
[0006] FIG. 3 is a diagrammatic representation of a decorative sleeve cap
for a railing support post, consistent with certain embodiments.
[0007] FIG. 4 is a cross-sectional view of an assembly of a railing support
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CA 02894334 2015-06-16
post, a decorative sleeve, and a decorative sleeve cap, consistent with
certain
embodiments;
[0008] 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;
[0009] FIG's 6A and 68 are further cross-sectional views of an assembly
of a railing support post, a decorative sleeve and exemplary rail fitting,
consistent with certain embodiments;
[0010] 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;
[0011] FIG. 8 is a view of a railing assembly utilizing two railing support
posts, consistent with certain embodiments;
[0012] FIG. 9 is a flow chart of a method for manufacturing a railing
support post, consistent with certain embodiments;
[0013] FIG. 10 is a diagrammatic representation of a base support plate,
consistent with certain embodiments;
[0014] FIG. 11 is a view of the section 11-11 shown in FIG. 10;
[0015] 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;
[0016] FIG. 13 is a diagrammatic representation of a lower portion of a
cable railing support assembly viewed from above, consistent with certain
embodiments;
[0017] FIG. 14 is a view of the section 14-14 shown in FIG. 13;
[0018] 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;
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[0019] FIG. 16 is a side view of the upper plate shown in FIG. 15; and
[0020] FIG. 17 is a diagrammatic representation of a lower portion of a
cable railing support post assembly, consistent with certain embodiments.
DETAILED DESCRIPTION
[0021] 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.
[0022] 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.
[0023] 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.
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[0024] 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.
[0025] 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.
[0026] 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.
[0027] 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
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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.
[0028] While the
railing s=Jpport 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".
[0029] 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.
[0030] 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.
[0031] 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.
[0032] 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
CA 02894334 2015-06-16
the elongated member.
[0033] 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.
[0034] 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.
[0035] 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.
[0036] 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.
[0037] 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.
[0038] The decorative sleeve 200 is sized to pass over the elongated
member and the base support bracket of the railing support post.
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[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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
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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.
[0044] The decorative sleeve 200 may be attached to the sleeve support
112 of the railing support post via a fastener 408.
[0045] Together, the decorative sleeve 200 and support cap 300 enclose
the railing support post 300.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] 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
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example, the sleeve support, the decorative sleeve and the decorative cap may
be molded as a single plastic part.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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,
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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.
[0054] 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.
[0055] 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.
[0056] 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.
CA 02894334 2015-06-16
[0057] The railing support post may also be used in conjunction with many
kinds of lighting fixtures, should the need arise.
[0058] 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.
[0059] 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.
[0060] In an exemplary embodiment, the threaded receivers are evenly
spaced at approximately 3.09 inch spacing. However, other spacing may be
used.
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[0061] 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.
[0062] 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.
[0063] 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.
[0064] 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
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support may be attached by welding or bonding, for example. The manufacture
terminates at block 916.
[0065] 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.
[0066] 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.
[0067] 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.
[0068] 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
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support a decorative sleeve passed over the elongated member.
[0069] Optionally, at least one side potion of the upper plate is bent
upwards to facilitate alignment of a hollow decorative sleeve around the upper
plate.
[0070] 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.
[0071] 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.
[0072] In one embodiment, the elongated member is made of metal and
has a wall thickness of between 1/16" and 3/8".
[0073] 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.
[0074] 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.
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[0075] 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 decoratiw-, sleeve.
[0076] 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.
[0077] 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.
[0078] In FIG. 10, the raised platforms are substantially square.
However, other shapes may be used, such as elliptical, circular, triangular,
etc.
[0079] 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.
[0080] In one embodiment, the height of the steps is approximately 1/16".
CA 02894334 2015-06-16
In a further embodiment the height of the steps is greater than 1/16".
[0081] 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.
[0082] 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.
[0083] 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
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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.
[0084] 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.
[0085] 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 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.
[0086] FIG. 16 is a side view of the upper plate shown in FIG. 15. This
view shows the corner 1502' at approximately 90 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.
[0087] 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.
[0088] In accordance with various embodiments presented herein, a cable
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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.
[0089] 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.
[0090] 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.
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[0091] 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.
[0092] 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.
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