Bracket system for attaching elongated members

Abstract

Elongated members such as the rail and post of a baluster are attached by a U-shaped bracket strip affixed on a surface of the post and received in an end of the rail, being attached to each by fasteners. A terminal fitting forms a sleeve that is provided or is shaped during installation to conform to the surface of the post. The terminal fitting sleeve extends over the end of the rail and over the bracket, to abut against the post, concealing the end of the rail. The rail can have a flush cut load bearing internal member such as an aluminum channel or rectangular tube. A polymer outer cover forms the surface of the rail. The bracket system makes convenient, useful and structurally strong rail-to-post connections at various angles and in situations where the rail needs to meet the post at a polygonal edge.

Description

BACKGROUND OF THE INVENTION

The invention relates to attachments of elongated members at an angle, particularly joints between elongated rails and posts. The invention is applicable, for example, to stair, deck or balcony railings and to fences of various types, and also can join rails and rail-like elements to adjacent walls as well as line posts, end posts and corners, porch posts, newels and the like.

PRIOR ART

Joints between elongated members are made in various indoor and outdoor contexts in which the members may lend structural support or may provide decoration, or both. An example is a joint between a vertical standing member (a post) and an elongated member that connects to the vertical one (a rail). In buildings, posts generally support beams that are exclusively horizontal and carry further structures whose weight is transferred to the posts. In open work structures such as fences and railings, rails may support elements with a decorative and/or confining function, such as spindles, pickets or fence panels, and the rails may join to the posts at various angles. In a joint comprising a rail and a post, either of the rail and the post could attach endwise to the lateral side of the other. For convenience, this disclosure generally refers to the rail as being the member that abuts endwise against the lateral side of the post, regardless of orientation.

Depending on the particular structure, a post may have rails attached endwise to the post on one or more places along and around the lateral sides of the post. A rail may pass over the end of a post such that the top end of the post attaches endwise to a surface along an underside of the rail. It is advantageous for appearance and structural strength if the end of whichever member abuts endwise is shaped to form-fit against the side of the member that abuts laterally, with no gap. Also, the two members need to be securely connected across the joint if the structure is to bear any appreciable load.

For convenience of explanation, all elongated members joined end-to-lateral-side are termed posts and rails in this discussion. This is in keeping with the primary application of the invention to railings, fences and related structures such as balustrades, banisters, handrails, trellises, lattices, arbors, pergolas and the like. One or another of the members (posts and/or rails) may be contribute structural strength and support, as in the example of a porch post, or manual assistance, such as a stairway banisters, or confinement for safety or otherwise, such as perimeter railings and fences. These and other similar uses are apt for the joint of the invention. Decorative appeal is another important aspect. Thus, there are aesthetic and strength considerations to how the structures are arranged and attached.

The vertical post is generally the basic founded structure of an attached post and rail, although that situation is not a necessity. One or more rails often connect between two spaced posts (or between a post and another structure) and may be supported exclusively by a post at one or both ends of the rails. Often two or more rails are attached between successive posts at vertically spaced points. Spindles, pickets, slats or panels may be affixed between or to the rails. The rails may be inclined, crossed and optionally affixed together in a cross-buck configuration. The rails and posts may be configured to carry panels or other elements. A post may be attached to a fixed structure at its base, or may be embedded for part of its length as in the case of many fences having posts set in the ground. Usually a post is vertical, although the absolute orientation of the post is not important to the present invention.

In a fence or railing, a given post can be a line post, an end post, a corner post, etc., considering the placement of the post along the route of the fence or railing. A line post has rails attached on both opposite sides of the post. If the rails are co-linear, the post and the rails generally are in a common plane with one another. Co-linear rails may have longitudinal axes oriented at an angle relative to the axis of the post. This is usually the case with a stair railing or a fence on a slope, because the rails are parallel to the surface of the passage, which may be inclined to horizontal, whereas posts are usually vertical. The slope can change, so that the rail between two posts is arranged at a different slope than the rail between the next posts, for example where a horizontal railing leads into a sloping banister. In addition to those possible orientations, the post can be at the corner where a line of fencing or railing follows an acute, obtuse or right angle in plan view.

As a result of these different possibilities, one or more rails can join with a post at various different angles. If the longitudinal axes of a rail and post intersect, the two axes define a plane, but two rails attached to the same post may be in divergent planes. The axes of the post and either rail in the respective plane can meet at various angles from near zero to near 180°.

In order to make a simple abutting joint between a rail and a post, it is necessary to take into consideration the shapes of the post and rail and the angle at which they are to meet. If the post is cylindrical, the end of the rail needs to have a semi-cylindrical channel formed across the end of the rail at the relative angle of the joint. If the post is a different shape (e.g., a polygon) the channel needs a different shape to make the end of the rail complementary with the surface of the post. For a polygonal post such as a square cross section, attention is needed as to whether the rail meets the post at a face or at an angle between faces. Curved or complex shaping of the end of a rail (or other elongated member), so as to complement the shape of the side of a post or other elongated member to which the rail is to abut, is known as a coping cut.

A coped shape on the end of a rail may contribute to fixing the attachment of the rail to the post, depending on the shape of the post. However some sort of fastener is also required, at least to hold the joint against separating from tensile forces. Compression forces are resisted insofar a the end of the rail abuts against the surface of the post. It would be advantageous if the necessary structural connections could be made using some sort of fitting disposed to connect the rail to the post, but such a fitting might disadvantageously space the end of the rail from the post or substantially complicate the problem of shaping the end of the rail to complement the surface of the post.

Conventional joints for attaching rails to posts are intended to bear nominal force, and can be more or less successful depending on the structure and the situation. Toe-nailing a rail to the post is one alternative, but is not highly resistant to tension. Shear forces can be borne by placing a cleat adjacent to the rail, for example under the rail to bear vertical forces, the cleat being attached to the post by a fastener. A cleat likewise can help to resist tension, if attached both to the post and the rail using suitable fasteners. However cleats and similar fittings are not visually appealing because they detract from the extent to which the rail seems to abut and join directly to the post.

Assuming that the post is rectilinear and the rail is to attach at a face on a side of the post, the rail needs to be cut at the required angle to provide face-to-face contact. In a simplest case, the angle could be a right angle cut normal to the axis of the rail. However, the cut might need to slant, e.g., if the axes of the rail and the post do not meet at a right angle. If the rail also is angled relative to the face of the post in plan view, then the cut needs to slant in two perpendicular planes. If the cross section of the post is not a regular polygon or if the rail is to join the post at a corner of a polygon, the cuts are even more problematic. Fitting the rail to the post can become complicated.

Skilled craftsmen deal with these and similar complications in wood structures, for example by coping the end of the rail to match the shape of the surface of the post at the angle at which the rail is to meet the post. It would be advantageous if similarly close fitting joints could be achieved without the need for a high level of skill in cutting the ends of the posts. Apart from appearance, a close fit joint is likely to be stronger than one with gaps. It would be advantageous to provide a good structural connection so as to bear loads.

As shown, for example, in U.S. Pat. No. 6,017,019—Erwin, it is possible to affix a socket on the post, having a depth sufficient to conceal an end of an adjoining rail that is not cut to a shape complementary with the post. Assuming, for example, that the rail is cut flush at a right angle to its axis of elongation and joins the post at a non-right angle, then the end of the rail can touch the post on the acute angle side of the joint and but is necessarily spaced from the post on the obtuse angle side.

The socket in Erwin '019 is a hollow box with surface flanges that affix to the post with fasteners. The box has an opening that is complementary with the external cross section of the rail. However, if the rail is to meet the post at an angle, such as the connection of an inclined balustrade to a vertical newel post at the end of a stairway, the opening needs to be enlarged to admit the inclined rail. In Erwin, the box can have an opening for the rail that is exaggerated in size in one direction, namely parallel to the inclined rail. If this socket solution is applied to a rail of round cross section, for example, the opening into the socket box has a minor axis equal to the diameter of the rail, and a major axis that varies inversely with extent to which the angle of incidence differs from a right angle.

If the rail is flush cut perpendicular to its axis and joined to the post at an acute\obtuse angle using a socket box, the box needs to be as deep as the gap between the post and the end or the rail on the obtuse side of the angle. If the same inclined rail is slant cut, or if its end is coped to roughly complement the post, then the end of the rail can be concealed by a relatively shallower socket box. Deep socket boxes are not visually appealing.

U.S. Pat. No. 5,873,671—West teaches a socket fitting comprising a stub that protrudes from a mounting plate that is affixed on the surface of a post. The mounting plate is the bottom of a socket box as in Erwin '019 and must itself be shaped to fit the surface of the post. West has a hollow rail (a tube) that may be slant cut. The stub on the mounting plate protrudes generally at a right angle from the post but the stub is slant cut, whereby the rail can be inclined relative to the stub. As a result, the stub does not fill the hollow of the rail, which has structural drawbacks, but a connection can be made.

Examples of posts and brackets for rails that attach at right angles are found, for example, in U.S. Pat. No. 4,280,686—Wack (a bracket receiving fasteners directed oppositely into the post and rail, respectively); U.S. Pat. No. 5,143,472—Reed et al. (a base bracket with a telescoping cover); and U.S. Pat. No. 6,039,307—De Zen (a post bracket that telescopically receives an end of the rail.

It would be advantageous to provide a structure for attaching a rail to a post such that there is a secure mechanical connection for resisting tension as well as shear. Such an attachment or joint should have a minimum of required parts, should be easily assembled, and should produce a substantially flush and gap-less connection of the parts, at a number of selectable connection angles.

SUMMARY OF THE INVENTION

One of two elongated members (such as a post or rail) is to be attached endwise to a lateral side along the other of such members. At least the member abutting endwise has an internal support structure enclosed in an outer hollow body, such as an aluminum channel in a polymer extrusion. A bracket makes a structural connection between the internal support structure and the lateral side of the other member, using fasteners. The bracket can be configured for various angles. An adapter sleeve fits over and extends the shape of the outer hollow body at the end, covering the bracket. The adapter sleeve can be cut at a slant, coped or similarly fit against the surface at the lateral side.

It is an object of the invention to provide a rail-and-post connection that is versatile for accommodating different construction situations such as different relative angles of the rail and post, structurally strong, easy to assemble and attractive in the finished state. Another object is to do so in elements that are inexpensive but durable and substantially maintenance free.

According to an aspect of the invention, elongated members such as the rail and post of a baluster are attached by a U-shaped bracket strip affixed on a surface of the post and received in an end of the rail, being attached to each by fasteners. A terminal fitting forms a sleeve that is provided or is shaped during installation to conform to the surface of the post. The terminal fitting sleeve extends over the end of the rail and over the bracket, to abut against the post, concealing the end of the rail. The rail can have a flush cut load bearing internal member such as an aluminum channel or rectangular tube. A polymer outer cover forms the surface of the rail. Either or both of the internal member and the polymer outer cover can be slant cut or coped, but the invention minimizes or eliminates the need for complex coping cuts. The bracket system makes convenient, useful and structurally strong rail-to-post connections at various angles and in situations where the rail needs to meet the post at a polygonal edge.

According to an inventive aspect, the U-shaped bracket strip fits snugly into the opening in the load bearing internal member, and the opposite ends of the bracket strip are folded to provide feet at angles that determine the relative orientation of the body of the U-shaped bracket relative to the post. This also determines the nominal angle of the rail. The bracket strips are inexpensive, and can be provided pre-formed to a number of angles from which the installer selects the appropriate angle. It may also be possible to shape the bracket on site, but this can be complicated in the same way as complex coping cuts, and therefore is not preferred.

According to another aspect, the terminal fitting sleeve and/or the bracket strip is provided in standard or incremental angles to accommodate nominal construction angles such as slant endwise abutting joints of rails to newel posts. Likewise and additionally, incremental or standard angle forms of bracket and terminal sleeve part can be provided, e.g., for 45, 30 or 22.5 degree divisions in angles as viewed in plan, and other standard forms. According to another aspect, the terminal fitting sleeve can be pre-coped for a given post shape and for meeting at the face of a polygonal side or at a corner between faces.

A number of further objects and aspects will be apparent from the following examples and the associated discussion of variations of which the invention is capable.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features and advantages of the invention, as well as other aspects and routine extensions of the invention, are apparent from the following detailed description of examples and preferred embodiments, to be considered together with the accompanying drawings, wherein the same reference numbers have been used throughout to refer to the same functioning parts, and wherein:

FIG. 1 is an exploded partial perspective view showing an exemplary embodiment of the invention, applied to a perpendicular mid-face attachment of a post and rail.

FIG. 2 is an elevation view corresponding to FIG. 1, showing the completed assembly in the area of the joint.

FIG. 3 is an exploded isometric view in which the invention is applied to attaching the rail at a corner between faces on the post.

FIG. 4 is an exploded isometric view in which the rail is attached at a rounded surface.

FIG. 5 is an exploded isometric view in which the rail is attached to a face of the post as in FIG. 1, but is inclined downwardly, for example as an inclined banister along a stairway.

FIG. 6 is an exploded isometric view in which rails are attached on opposite sides of a post, in this example defining an obtuse angle of incidence.

FIG. 7 is a section view longitudinally through the rail as shown in FIG. 6, demonstrating the structural connections between the parts.

DETAILED DESCRIPTION

A number of exemplary embodiments of the invention are described herein with reference to the drawings. These embodiments are examples intended to demonstrate aspects of the invention in different forms or separately. Not all the aspects are required in all embodiments of the invention, and the illustrated embodiments should be regarded as exemplary rather than limiting.

Furthermore, this description is written to refer to examples that do not exclude comparable structures and functions. For example, the vertical member of a post and rail construction is often the thicker and more securely mounted of the two members that are joined, is most often vertical, and is generally called the “post.” The rail is likely to be more lightweight and less securely affixed to other structures. The rail is usually abutted endwise against the lateral side of a post at the joint. Although often horizontal, rails sometimes reflect the ground contour or the inclined slope of a stairway. Notwithstanding these conventional aspects, it is entirely possible that the “post” could be horizontal (or otherwise aligned) or that a “rail” could be a vertical or securely mounted larger structure, or the joint can involve a rail to which a post is abutted endwise at the joint.

The embodiments discussed herein as examples concern post and rail or railing arrangements that are most frequently encountered in exterior projects such as porches, decks, verandas, gazebos and the like. The subject matter is also applicable to other interior or exterior uses such as balconies, balustrades, pool enclosures, malls and other public access uses, or fences, barriers, and structures of various descriptions and functions.

Therefore, in this description, terms denoting relative directions and orientations such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” should be construed to refer to the orientation as then being described or as shown in the drawing under discussion. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein elements are integral parts of a whole, or 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 or as apparent in view of the described functions of such elements.

Referring to FIGS. 1 and 2, according to an inventive aspect, elongated members such as the rail 20 and post 30 are attached to one another using a U-shaped bracket strip 40. The bracket strip 40 is affixed on a surface of the post 30 and generally defines a tenon have a shape that is complementary with and is received in the hollow internal contour of an end of the rail 20. The bracket strip 40 is attached to each of the rail 20 and post 30 by fasteners 52, 53 such as sheet metal screws, rivets or similar fasteners.

A terminal fitting 60 comprising a sleeve or channel that fits over the rail 20 adjacent to the joint, provides a transition from the rail to the post. The terminal fitting 60 is shaped on its end facing the post 30 to conform to the surface of the post. That is, the terminal fitting conforms to the shape of the surface of the post at the point of attachment, which might be any of various shapes. The terminal fitting also is chosen, or might be trimmed, for the angle of incidence between the rail 20 and post 30.

In FIGS. 1 and 2, the end of the transition fitting is flush, namely formed or cut on a plane normal to the longitudinal axis of rail 20, so as to join perpendicularly to a face 32 of post 30. According to an inventive aspect, the end of the rail 20 need not be carefully cut to conform to the post 30, because the transition fitting 60 conforms to the surface of the post while enclosing over any gap between the end of rail 20 and the surface of post 30.

FIG. 1 shows an exploded view and in FIG. 2, the joint is assembled, thereby concealing the bracket 40. The bracket 40 provides a secure structural connection between the rail 20 and post 30, and fixes the relative positions of the rail 20 versus the post 30. During assembly, the terminal fitting 60 is moved to the end of rail 20 so as to extend from the end of the rail 20, enclosing over the bracket 40 and any gap between the rail 20 and post 30, to rest against the post 30. Thus the rail is secured structurally and appears to abut closely against the post due to terminal fitting 60.

The joint as shown is strong. The fasteners 52 that affix bracket 40 to post 30 fix the bracket rigidly to the post. In the embodiment shown in FIG. 1, the bracket 40 is oriented so that forces that would apply leverage in a direction tending to rotate the rail downwardly around the joint (such as the force of gravity on rail 20 and whatever the rail may carry) are borne in the plane of the material on the side legs of bracket 40. The bracket 40 is most rigid in this direction.

Additional fasteners 53 affix the rail 20 to the bracket 40. It is possible to arrange the joint so that the transition sleeve 60 is also captured in position by fasteners 53, or sleeve 60 can be affixed using adhesive or a dab of silicone caulk or the like. Thus assembly is a simple process. The bracket 40 is aligned for the desired lateral orientation of rail 20 (normally horizontal) and attached to post 30 at the required height, using two or four sheet metal screws 52. The rail is then pushed onto the protruding end of bracket 40. With the rail held temporarily in position, fasteners 53 are inserted and tightened, so as to couple rail 20 to post 30. The sleeve 60 is advanced along rail 20 to bear against the post 30, either before inserting the fasteners, so that the fasteners also hold the sleeve, or afterwards, so that the sleeve 60 also covers and conceals the heads of the fasteners. This technique structurally engages rail 20 to bracket 40 and thus to post 30, and also decoratively and structurally attaches the sleeve 60 to complete the joint and extend the rail precisely into complementary position against post 30.

The inventive arrangement relieves the installer of the need to make finely measured or geometrically complex coping cuts at the end of the rail. Nevertheless, the end of the rail conforms neatly to the surface of the post, concealing any gap and forming a tight and strong joint. In the event that coping cuts are necessary, it is much easier to accomplish cuts on the polymer sleeve 60 than on the rail 20.

In the embodiment shown in FIG. 1, the rail 20 has an internal load bearing member 22 such as an aluminum channel or length of rectangular tubing. The member 22 can be coextensive with the outer part 24 of rail 20 (i.e., cut flush with the end of part 24), or can protrude as shown by a short distance at the end of rail 20. The outer part can comprise an extruded polymer tube forming cover 24, shaped as shown in a conventional hand-rail cross section with a wider upper part and narrower lower part for gripping. Other shapes are also possible for defining a decorative or functional outer surface for rail 20.

Assuming that the internal load bearing channel or similar structure 22 protrudes from the cover 24 as shown in FIG. 1, it is possible to attach the rail to the post structurally by passing a fastener through channel 22 or the like and into the bracket 40, without involving the polymer cover part 24. The polymer cover part 24 can be dimensioned and configured to slide on the load bearing member 22, so that the cover can be moved toward or away from post 30 on the internal part 22 of rail 20. In that case, the cover can be dimensioned to pass over the heads of fasteners 53, before or when moving the transition sleeve part 60 into position against the post 30. As another alternative, the load bearing member 22 can be coextensive with the polymer cover 24 rather than protruding, in which case the fastener 53 can pass through the transition sleeve 60, through the cover 24 and then into the internal structural part 22.

The internal structure of the polymer tube forming cover 24 can have one or more ridges 25 that are positioned to engage with the surfaces of the internal structural tube or channel 22. This tends to further stiffen the rail structure. The bracket as shown in FIG. 1 preferably is dimensioned substantially to fill or complement the inside contour of the opening at the end of the internal load bearing channel or similar part 22. Thus the channel is held in position by bracket 40, and bracket 40 generally supports the internal channel 22 against collapse, in the manner of tenon fit into the hollow end of rail 20.

Advantageously, the bracket system as described is configured to make convenient, useful and structurally strong rail-to-post connections wherein the post presents various shapes. Thus, in FIG. 3, a similar structure is provided wherein the joint is aligned to an edge or corner 34 of post 30. The sleeve member 60 in this case has an edge contour 62 that is generally a 45° vee shape, for fitting closely against the surface of the post 30, namely against the face surfaces 32 and associated corner 34. In the same manner in FIG. 4, the analogous post, shown as a cylindrically curved sheet port 35, is complementary with an edge contour 62 of sleeve 60 that is in this case rounded. These examples show that the sleeve member 60 can be arranged on its end facing the post to complement the surface and provide a close fit.

As apparent from these embodiments, the invention provides a post and rail construction in which the post 30 has a lateral surface 32, 34, 35, etc. to which an end of the rail 20 is to be affixed. Each of the post and the rail have longitudinal axes, but they are oriented at an angle to one another such that the end of one, namely rail 20 in the foregoing examples, has an end that abuts against the other, in these examples post 30.

The structural part of the connection is made in large part by bracket 40, which is securely affixed to the surface of the post 30 by fasteners 52. The could be solid of otherwise shaped, but advantageously as shown comprises a strip of sheet material extending from the surface of the post 30 for a distance along the longitudinal axis of the rail 20. As shown in FIG. 3, the bracket 40 comprises a strip bent in a U-shape, having two support feet 42 at the ends of the U-shape, spaced-apart leg parts 44 and a U-bottom web 46, all of which are portions of an integral length of sheet metal strip.

In the embodiments shown in FIGS. 1-4, the feet, legs and bottom of the strip are bent at right angles along lines perpendicular to the elongation of the strip before bending. As a result, the bracket 40 provides a substantially rectilinear tenon shape protruding from post 30. In the case of FIGS. 1-3, for example, the bracket forms a tenon that is aligned perpendicular to the axis of the post, but this is not a requirement, as will be apparent in connection with further examples. In any case, the strip that forms the bracket 40 is bent so that the edges of the strip reside along the edges of a rectilinear plug shape or tenon that protrudes along the axis of the rail 20. This tenon is affixed securely to the post 30 by fasteners 52 that engage the post 30 through fastener holes in each foot part 42 of the bracket strip.

Two fastener holes are shown in the foot part 42 visible in FIG. 3, one such hole being occupied by a fastener 52 that in the example comprises a screw. It is likewise possible to place two or more fasteners per foot 42. The size and type of fastener can be varied to correspond the expected loading, for example from a lightweight sheet metal screw or pop rivet for attachment to a hollow polymer or sheet metal post to a heavy lag bolt threaded into a solid wood post, or another similar arrangement.

FIGS. 1 and 2 illustrate examples wherein the post and rails are both hollow elongated members, such as sheet metal or hollow polymer tubes. In the example, shown in FIG. 3, the post comprises a polyvinyl chloride (PVC) polymeric square tube fit over a wooden core post 37 that fits snugly in the tube. The preferred fastener is a #10 by two inch stainless steel pan head screw with a square drive head.

The rail 20 is hollow for at least a short distance along the end of the rail, forming an opening complementary with the strip of sheet material, which as bent into the U-shape forms a tenon. The rail is affixed to the strip of bracket 40 at the opening, thereby structurally affixing the rail to the post. In an embodiment as in FIGS. 1 and 2, wherein the rail 20 is cut flush at an end affixed to the bracket 40 and is joined perpendicularly to post 30 at a flat face 32 and at right angle, the end of the rail 20 can be placed relatively close to the surface of post 30. The terminal fitting slides up against the surface of post 30, being telescopically slid down the rail 20 to reset against post 30. A relatively flush fit is possible as shown in FIG. 2. The terminal fitting can be retained frictional, fixed in position with a dab of adhesive or caulk, or attached using the same or other fasteners.

In the event that the end of rail 20 is cut off at a right angle but joins to the post 30 at a corner as in FIG. 3 or joins to a round post 30 as in FIG. 4, the right angle cut end of the rail does not complement the cross sectional shape of the post. However the terminal fitting can be shaped to complement the post as shown. Thus, for example, the cut end of the post 20 in FIG. 3 may abut the post at the corner and be spaced from the post in the area of the supporting feet 42 of bracket 40. By providing the vee shaped cutout 62 for the square post cross section shown in FIG. 3, or a rounded contour 62 as in FIG. 4, the terminal fitting 60 is brought flush against the post 30. The terminal fitting matches the predetermined angle of the rail relative to an axis of the post, and the terminal fitting is pre-formed or trimmed to a shape that complements a surface of the post at said predetermined angle.

In the embodiments of FIGS. 3 and 4, an end of the rail 20 at the joint, and more particularly the portion of the rail surrounding the opening that receives the bracket 40, is spaced from the surface of the post by a gap caused by the fact that the end of the rail is not cut to the same contour as the surface of the post 30. In the case where the rail joins to the post at a right angle, the terminal fitting 60 is cut on a vertical line corresponding to the surface of the post, having a shape resembling part of a square in FIG. 3 or part of a circle in FIG. 4. The rail can optionally also be cut or coped on the end abutting the post so as to provide less gap. The gap generally does not detract from the structural connection of the post and the rail, which is robust due to the attachment of the rail to the post through bracket 40 as opposed to attachment relying primarily on complementary end shapes. It is possible to make a careful coped cut but the invention makes an exact fit less crucial. The structural connection is made from the rail 20 to the bracket 40 and from the bracket 40 to the post 30. The terminal fitting accurately complements the shape of the surface of the post, and can accommodate a predetermined angle relative to an axis of the post, the terminal fitting instead of the post or rail is trimmed, if necessary, to a shape that complements the surface of the post at said predetermined angle.

In the embodiment shown, the rail 20 comprises an inner load bearing member 22 that defines the an opening that fits over the bracket 40, namely extending along the longitudinal axis of the rail from the end adjoined to the post 30. In the embodiment shown, the inner member 22 is a channel that opens downwardly, having a rectangular contour for the opening between the channel walls. The inner load bearing member 22 could alternatively comprise another shape besides a channel, such as a closed tube of a rectangular or other cross section, a flanged shape such as a length of angle iron, an I-beam cross section wherein one or both sides of the I-beam shape receives a bracket 40, a folded sheet metal shape such as that of a galvanized steel building stud, etc.

The rail member 20 comprises an outer covering 24 on the load bearing internal member. The outer covering can be adhered tightly on the internal member 22 or can be loose enough to slide longitudinally along member 22. Preferably, the outer cover is at least snugly fitted to provide friction against sliding. The cover can be adhered by shrinkage onto member 22 or by adhesive or a similar technique. In the exemplary embodiments shown, the inner load bearing member 22 protrudes beyond the end of the outer covering 24 at the end of rail 20 to be affixed to the bracket. Such protrusion is not absolutely necessary but has the advantage of enabling the installer to concentrate on the mechanical attachment of the structural member 22 of rail 20 to the bracket 40 and thus to post 30.

FIGS. 1, 3 and 4 show examples wherein the bracket 40 comprises a strip of sheet material bent into a U-shape at right angle bends between the legs 44 and the bottom web 46 of the U-shape, with the direction of elongation of the strip being perpendicular to the axis of the post 30, laterally oriented relative to rail 20 and with the center line of the U-shape extending along the center line of rail 20. This arrangement is preferred but other specific structures and orientations are also possible.

The U-shape of the bracket can be more or less rounded, for example having a circular arc instead of a flat web at the bottom 46 of the U-shape. The U-shape can be partly formed by two or more parts, such as two spaced L-shapes that each correspond to one of the feet 42 and sides 44. The orientation of the bracket can be provided by a strip with a center line parallel to the post axis rather than perpendicular as shown in the examples. Although such arrangements are possible, the arrangement shown in the figures is advantageous in that the bracket 40 tends to align rail 20 perpendicular to post 30 because bracket 40 is stiffer in a direction parallel to the plane of the side legs 44 than perpendicular thereto. Of course, in a given installation, it may be desirable to stiffen the connection in one direction more than another, in which event the bracket 40 can be oriented accordingly.

Similarly, the strip forming bracket 40 as shown is formed in a U-shape having both ends 42 turned flat and attached to the surface of post 30. In a structure that requires less load bearing capacity, a similar bracket 40 could have just one foot or could have the shape shown but only require that one foot be attached. Such choices can be made in a given installation to accommodate tradeoffs between structural strength versus ease of assembly and/or cost.

In each of the foregoing embodiments, the rail is shown as meeting the post at a right angle in the plane that includes both the post and the rail. (In the orthogonal plane, the orientation of the rail is variable around 360° by suitably placing bracket 40 at a flat face as in FIG. 1 or a corner or curve as in FIGS. 3 and 4.) FIGS. 5a, 5b show that the relative angles of the post and rail need not be a right angle. As also shown in FIG. 8, it may be desirable, for example, to provide a rail 20 that meets a newel post at an angle that is parallel to the pitch of a stairway, and in the same structure to provide another rail that meets one or more posts at a right angle.

An inclined rail arrangement as in FIGS. 5a, 5b can be accommodated by providing a bracket 40 that is shaped as already described, from a strip of sheet metal that is bent into a U-shape wherein the feet portions are attached to the post and the body of the U-shape extends in the direction of the rail 20, being received as a tenon or locating pin in the rail 20, e.g., in a structural member 22 thereof. More particularly, the bracket extends such that the edges of the bracket, namely the opposite sides of legs 44 and end web 46 in FIG. 5b, fit into the opening in the end of rail 20, particularly inside the load bearing channel or tubing member 22 thereof.

In FIG. 5a, if the channel or tube 22 is cut off flush at a right angle to the axis of rail 20, then when the rail is mounted and moved along bracket 40 to abut endwise against post 30, the edge of the flush cut rail can come into contact with post 30 only on the acute angle side of the post/rail joint (namely the underside of the rail in FIG. 5a). On the opposite or obtuse angle side, there is a gap between the end of the rail 20 and the surface of post 30 (specifically between the end of flush cut channel or tube member 22 and the post). The gap is a function of the vertical thickness of rail 20 and of the acuteness of the angle at which the rail meets the post.

The terminal fitting 60 shown in FIG. 5a has a terminal fitting 60 with a facing edge 62 that is inclined at a complementary angle so as to rest flush against the surface 32 of post 30, and thereby to bridge over the gap between the rail 20 and the post 30 due to their meeting at an acute angle. Fitting 60 also has a sufficient dimension along the axis of rail 20 to cover over the protruding end of internal channel 22 in an embodiment wherein the channel protrudes from the decorative outer cover.

The terminal fitting member 60 can comprise a PVC, polypropylene or other polymer form, preferably injection molded so as to form fit on the outside of the outer part 24 of rail 20. For example, the inside of the terminal member 60 can have a nominal clearance of 0.001 to 0.005 inch, such that the terminal member can slide easily over the surface of outer part 24. The terminal member 60 has a facing edge 62 that can be is preformed to a nominal shape for standard building construction situations, and is also capable of being trimmed to fit substantially more easily than one might trim the end of the rail 20 comprising the internal channel 22 (or similar shape) and outer part 24 of rail 20. As so provided or trimmed, the terminal fitting part 60 has at least one edge 62 that is parallel to a surface of the post 30 when the rail is installed. The associated fasteners 53 that affix the rail to the post can also affix the terminal member 60, or a separate fastener (not show) can be placed in a manner substantially like fastener 53 as shown but used specifically to hold the terminal member 60 to the decorative rail part and/or to the internal structural member 22. Thus the terminal sleeve member 60 can be affixed by screws 53, or by separate screws (not shown) that extend into rail 20 or bear against rail 20 in the manner of set screws. As mentioned above, the sleeve members 60 can be adhered using adhesive or caulk.

The square post shape shown in FIG. 1 is an example of a polygonal cross section. The post could have any number of sides, and the terminal fitting 60 can fit against the post at the sides and over the junction between sides, by forming the facing edge 62 to a shape that is complementary with one or more such faces of the polygonal cross section. The facing edge 60 thereby also conforms to any junction(s) between such faces, given the angle of incidence of rail 20 to post 30. This same attribute also allows the surface of abutment to be curved and the terminal fitting edge 62 can nevertheless fit flush against post 30 by having a shape the is appropriately complementary.

Often, building constructions call for standard angles. FIG. 1 illustrates an angle of 90° between the post and rail axes and 90° between the associated face of the post 30 and the rail axis. FIG. 3 illustrates 90° between the post and rail axes but 45° for the faces of two adjacent faces 32 of post 30. In the illustrated case, the angular location of the rail axis falls at a line 34 between post faces 32, such that the complementary shape of the facing surface 62 of terminal part 60 is vee shaped. It is possible to make a similarly inclined junction with the rail 20 engaged at 45° relative to a face 32 but attached only to such face 32, in which event the rail would not radiate.

FIG. 6 illustrates an embodiment in which two rails 20 meet a post 30 on opposite sides, each rail 20 having an axis oriented at 90° relative to the post axis and 22½° relative to the associated face 32. In this case, the junction encompasses the edge between faces of the post, whereby surface 62 is an asymmetrical vee shape. FIG. 7 illustrates how the parts of this construction can be arranged and connected by fasteners 52, 53.

A limited number of standard shapes for bracket 40 and terminal part 60 are normally sufficient to accommodate many standard orientations, for example of a rail and banister arrangement as shown in FIG. 8, and further assuming that the posts 30 need not be round. The brackets 40 are made of sheet metal and thus are relatively easily deformable to orient a bracket 40 for a right angle connection of a rail to a post at the required angle of approach to a post that may have any number of polygonal sides. Thus the same form of bracket will usually suffice in the case of FIGS. 1, 3, 4, 6. In the case of FIG. 5a, the fold line between the feet 42 of the bracket 40 can be inclined relative to the edges of the bracket strip to make the bracket inclined as shown in FIG. 5b. The directions for assembling the post/rail joint can provide a guide for determining the angles needed for the respective bends at predetermined connection angles.

In standard sizes and angles, parts can be supplied as specified or in a kit that accommodates standard connection points and angles for building post and rail structures using the invention. Standard connections of right angle post/rail axes with connections at 90° relative to a post face 32, or at a 45° or 22½° are common types. Connections at 45° to a face could need a symmetrical vee on the terminal part 60 or a lateral incline at that angle. Connections at other angles are altered as apparent for reasons of geometry. The complication of differing stair pitch angles can be provided by supplying incrementally different bracket 40 and fitting 60 shapes, for example with several choices between the usual stair and railing pitch angles (normally from 27° to 37° relative to horizontal). It would also be possible to provide the installer with instructions on the correct bend angles for the bracket 40 and coping cuts for edge surface 62 of terminal part 60, to make a neat flush fitting connection by forming the bracket 40 and trimming the terminal part on site. However as discussed above, an aspect of the invention is to relieve the installer of such headaches, namely by providing pre-formed parts that meet most building construction situations.

The invention concerns the apparatus for the joint as described and also the associated method whereby an end of a rail is affixed to a post. This method includes providing a post 30 and a rail 20, at least part of the rail adjacent to the end being hollow, and determining an angle at which the rail is to meet the post. A terminal fitting 60 is selected or made to be complementary with a surface of the post at the required angle. During assembly, the terminal fitting can be placed temporarily on the rail at a position spaced back from the end of the rail. For receiving the end of the rail on the post, a bracket 40 is provided comprising a strip of material with at least one foot 42, the foot being bent so that the bracket extends at the necessary angle when the foot is placed against the surface of the post. The bracket is attached to the post using fasteners and the rail is then placed over the bracket so that the bracket is inserted into the hollow end of the rail. It is also possible to place the bracket in the rail first and attach the bracket to the post second. In any event, the foot is attached to the post at the surface of the post using fasteners 52. The terminal fitting 60 is moved along the rail 20 up to the post 30, thereby at least partly covering the bracket 40 and making a connection that appears closely direct from the rail to the post.

The rail 20 is attached to the bracket 40 by passing a fastener 53 through at least part of the rail into the bracket. The terminal fitting 60 can conceal the fastener thus passed through the rail. Alternatively, the terminal fitting 60 can be attached to the rail 20 by passing a set screw or penetrating fastener or by running the same fastener 53 through the terminal fitting 60 and well as through the wall of the rail 20, 22, into the bracket 40 therein. These different alternatives are shown in several of the drawings, particularly in that right angle joints (e.g., FIGS. 1 and 2) are apt for concealing fasteners 53 under sleeve 60. In round post contour or corner approach joints (FIGS. 3 and 4) the fasteners go through sleeve 60, etc.

The rail can be flush cut perpendicular to its extension, or can be cut at an incline. According to an inventive aspect, it is not necessary to go to great lengths to trim or cope the end of the rail. The terminal fitting is provided with a shape, either as supplied or as trimmed by the installer (more easily than trimming the rail) to complement the surface(s) of the post. The terminal fitting fits against the post at least at one of a flat face of the post, a flat face of the post at an angle of incidence, a rounded face of the post, a rounded face at an angle of incidence, a polygonal portion of the post, a polygonal portion at an angle of incidence, or another comparable arrangement whereby the end of the rail is to abut against a lateral side of the post.

The invention has been disclosed in connection with certain examples and embodiments but is not limited to the particular constructions herein disclosed and shown in the drawings, but also comprises any modifications or equivalents within the scope of the appended claims.

Claims

1. A post and rail construction comprising:

a post having a surface to which an end of a rail is to be affixed, wherein the post and the rail have longitudinal axes oriented at an angle to one another;

a bracket affixed to the surface of the post, the bracket comprising a strip of sheet material extending from the surface of the post for a distance along the longitudinal axis of the rail;

wherein the rail is hollow at least for said distance along the end of the rail, forming an opening complementary with the strip of sheet material, and wherein the rail is attached to the strip at the opening, thereby structurally affixing the rail to the post, wherein the rail is affixed to the bracket and is joined to the post at a predetermined angle relative to an axis of the post, and wherein the terminal fitting is shaped to complement a surface of the post at said predetermined angle.

2. The post and rail construction of claim 1, wherein at least part of an end of the rail at the opening is spaced from the post by a gap, and further comprising a terminal fitting on the rail, the rail at least partly bridging the gap. wherein the rail is cut flush at an end affixed to the bracket and is joined to the post at a predetermined angle relative to an axis of the post, and wherein the terminal fitting is cut to an shape that complements a surface of the post at said predetermined angle.

3. The post and rail construction of claim 1, wherein the rail comprises an inner load bearing member having an opening extending along an axis of the rail from the end, and the bracket is received in the opening.

4. The post and rail construction of claim 3, wherein the inner load bearing member comprises an elongated member forming one of a channel, a tube and a flanged shape.

5. The post and rail construction of claim 3, wherein the rail further comprises an outer covering, and wherein the inner load bearing member protrudes from the outer covering at the end affixed to the bracket.

6. The post and rail construction of claim 1, wherein the strip of sheet material comprises a length of said sheet material having a width, the strip being formed in a U-shape having at least one end defining a foot for attachment on a surface of the post.

7. The post and rail construction of claim 6, wherein the opening complementary with the strip of sheet material is substantially rectangular in cross section.

8. The post and rail construction of claim 1, wherein the opening in the rail is rectangular and the strip of sheet material comprises an elongated length of said sheet material having a width, the strip being formed in a U-shape along said length, the U-shape of the strip having a rectangular cross section with a side equal to said width, and being complementary with the opening in the rail.

9. The post and rail construction of claim 8, further comprising at least one fastener affixing the strip to the post and at least one fastener affixing the rail to the strip.

10. The post and rail construction of claim 2, wherein the rail is joined to the post at a right angle in at least one plane, and the terminal fitting has at least one edge that is parallel to a surface of the post.

11. The post and rail construction of claim 10, wherein the post has a polygonal cross section and the terminal fitting has a shape complementary with a face of the polygonal cross section.

12. The post and rail construction of claim 10, wherein the post has a polygonal cross section and the terminal fitting has a shape complementary with an angle between adjacent faces of the polygonal cross section.

13. The post and rail construction of claim 10, wherein the post has a curved cross section and the terminal fitting has a shape complementary to the curved cross section.

14. The post and rail construction of claim 2, wherein the rail is cut flush at an end affixed to the bracket and is joined to the post at a predetermined angle relative to an axis of the post, and wherein the terminal fitting is cut to an shape that complements a surface of the post at said predetermined angle.

15. The post and rail construction of claim 2, wherein the strip of sheet material comprises a length of said sheet material having a width, the strip being formed in a U-shape having at least one end defining a foot for attachment on a surface of the post, and wherein the foot is affixed to the U-shape at a bend that is inclined relative to the post such that the U-shape is elongated at an angle defining a bracket axis.

16. The post and rail construction of claim 15, wherein the opening complementary with the strip of sheet material is substantially rectangular in cross section, wherein the strip of sheet material is bent over between feet at each end of the strip attached on a surface of the post, and wherein insertion of the U-shape into the opening supports the rail at an angle determined by the bracket axis.

17. The post and rail construction of claim 16, wherein the U-shape of the strip has a rectangular cross section with a side equal to a width of the opening in the rail.

18. The post and rail construction of claim 17, further comprising at least one fastener affixing the strip to the post and at least one fastener affixing the rail to the strip.

19. A method for attaching an end of a rail to a post, comprising the steps of:

providing a post and a rail, at least part of the rail adjacent to the end being hollow;

determining an angle at which the rail is to meet the post;

providing a terminal fitting that is complementary to a surface of the post at said angle, and temporarily placing the terminal fitting on the rail at a position spaced back from the end of the rail;

providing a bracket comprising a strip of material with a foot, and bending the foot so that the bracket extends at said angle when the foot is placed against the surface of the post;

inserting the bracket into the hollow end of the rail and attaching the foot to the post at said surface of the post, thereby arranging the rail at said angle; and,

moving the terminal fitting along the rail up to the post to at least partly cover the bracket.

20. The method of claim 19, further comprising attaching the rail to the bracket by passing a fastener through at least part of the rail into the bracket, and wherein the terminal fitting conceals the fastener thus passed through the rail.

21. The method of claim 19, wherein the rail is flush cut, and further comprising shaping the terminal fitting to complement a surface of the post in at least one of a flat face of the post, a flat face of the post at an angle of incidence, a rounded face of the post, a rounded face at an angle of incidence, a polygonal portion of the post, and a polygonal portion at an angle of incidence.