Apparatus and method for attaching a rail and a post

Abstract

This invention generally relates to apparatus and methods for attaching a rail and a post. More particularly, the invention relates to novel brackets for attaching horizontal or diagonal rails to vertical posts. The bracket is fastened to the post and is inserted in an open end of a rail, and the rail is fastened to the bracket, including at various angles relative to the post. The present invention includes methods of attaching a rail to a post, railing systems comprising a rail fastened to a post, and kits including one or more brackets.

Description

FIELD OF THE INVENTION

This invention generally relates to apparatus and methods for attaching a rail and a post. More particularly, the invention relates to novel brackets for attaching horizontal or diagonal rails to vertical posts. The bracket is fastened to the post and is inserted in an open end of a rail, and the rail is fastened to the bracket, including at various angles relative to the post. The present invention includes methods of attaching a rail to a post, railing systems comprising a rail fastened to a post, and kits including one or more brackets.

BACKGROUND OF THE INVENTION

Outdoor decks are now common with houses, townhomes, condominiums, apartments, residences and other buildings. Outdoor (or exterior) decks typically extend from a doorway and provide a convenient, stable, and level surface for outdoor activities. Most decks are provided with one or more rails around their perimeters and along stairs associated with the decks.

Traditionally, decks have been made from wood, such as cedar, pine, redwood, and mahogany. However, decks can be made of other materials, including synthetic materials such as plastics, metals, and composites. Plastic deck materials have become very popular based on their aesthetic appearance, durability and low maintenance. Deck materials should be sturdy and capable of withstanding environmental conditions and typical use. It is also desirable to have deck materials that are relatively inexpensive, weather-resistant and easily installed and used.

Synthetic deck materials are currently available from numerous suppliers. Suitable synthetic deck materials include materials made from plastics (such as vinyl extrusions), metals (such as aluminum), composites (such as composites of plastic and wood), and other materials. It has become more common to use plastic materials and other synthetic materials for constructing fences or decks and for railings on decks. Vinyl fences and decks are aesthetically pleasing and easy to maintain compared to wood decks, but they pose challenges as well, such as in connecting various components together. For example, it can be challenging to fasten the rails to the posts, especially if the rail is to be fastened to the post at an angle, such as a rail for a staircase or a fence built over undulating terrain. Furthermore, it can be challenging to fasten the rails to the posts in an aesthetically pleasing manner, which is a important consideration particularly for outdoor decks.

Decks and fences generally include a number of vertical posts with one or more rails extending between the posts. The rails are fastened to the posts. Various techniques for connecting rails to posts are discussed below.

U.S. Pat. No. 4,360,285 discusses a connector to unite rail and post in a railing or the like by means of adjustable frictional engagement within the rail. A plurality of barbs extend from a leg of the connector and are bendable toward or away from the leg to adjust fit with the rail. The barbs have free ends oriented toward the middle of the connector, making the connector easier to assemble to the rail than to pull apart from the rail.

U.S. Pat. No. 4,919,394 discusses a railing construction comprising a plurality of upright posts, and a plurality of horizontal hollow rails having a generally rectangular cross section are connected between adjacent posts. Each rail includes a pair of side walls, a bottom wall and a top wall. Rail supporting brackets are connected to each post and each bracket includes a pair of spaced vertical side members that are disposed flatwise against the inner surfaces of the respective side walls of the rail. In addition, each bracket is provided with a horizontal lip that is disposed flatwise against the bottom wall of the rail. The end of the bottom wall of the rail has a notch having a length at least equal to the horizontal length of the side members of the brackets, so that the rail can be slipped downwardly over the bracket. The bottom wall of the rail and the horizontal lip of the bracket are provided with aligned holes which receive a bolt to connect the rail to the post.

U.S. Pat. No. 5,544,866 discusses a specialized metal bracket that permits the installation of wooden handrails between two upright supporting surfaces, such as posts, walls and the like, so that the bracket is not visible from the sides of the handrail. The bracket is L-shaped and recessed into the handrail on a side surface and bottom surface of the handrail. Two holes in a vertically-extending portion of the bracket are drilled adjacent to a bend in the bracket to permit trimming of a height of the bracket, as necessary. Two holes in the horizontally-extending portion of the bracket are spaced from the bend of the bracket to provide clearance from a post to facilitate use of a screwdriver to secure the handrail to the bracket. Both sets of holes are counter-sunk from opposite surfaces of the bracket so that the screws extending vertically into the handrail will not conflict with the screws extending horizontally into a post. Further, the counter-sunk holes provide for a snug fitting of the bracket into the handrail to aid in hiding the bracket from view from the sides of the handrail and rigidifying the connection of the handrail to support surface.

U.S. Pat. No. 5,544,865 discusses a support bracket for protective railing that may be adjustably positioned on a wall or other surface. The bracket is constructed such that when the bracket is loosely assembled, the placement of a rail segment on the bracket may be adjusted as desired within a limited range in one or more directions. After the placement of the rail segment has been adjusted, the component parts of the bracket are tightened to fix the rail segment in place. When assembled, the bracket forms a sealed unit with a smooth exterior that has a minimal tendency to collect dust, dirt and bacteria and that is easy to clean

U.S. Pat. No. 6,471,192 discusses a molded bracket for attaching a plastic rail to a plastic post. The bracket comprises outwardly extending fastener bosses for attaching the bracket to a post and providing the bracket with added support. The bracket further comprises a peripheral wall defining a shaped receptacle for receiving the end of a rail therein. The outwardly extending fastener bosses allow the bracket to be fastened to upright posts and to provide against vertical, horizontal and rotational movement.

U.S. Pat. No. 6,527,469 discusses a bracket for attaching a rail to a post. The bracket comprises a means for attaching said bracket to a post and means to provide said bracket with added support. Preferably, the bracket is bread shaped to fit a specific rail style well-known in the art. The bracket further comprises flanges to allow the bracket to be fastened to upright posts. The flanges are adapted to provide against vertical movement and against lateral movement through their opposing locations and their angled surface. Additionally, the bracket comprises an extended base to provide increased strength in response to force exerted on the attached rail.

U.S. Pat. No. 4,809,955 discusses a fence or railing which comprises a generally square vertical post formed, along each outer wall, with a U-shaped channel running its full length; the sidewalls of the channels defining two guide slots and the post further having a non-circular central open-ended bore. This central bore slidably and snugly receives, at its lower end, a pedestal which is fixed to a base plate. Mounted on the post is one end of an area-separation section made up of a top and a bottom horizontal rail interconnected by spaced vertical struts. The ends of the rails are inserted into one of the post channels and kept apart by flat spacer elements of identical constant cross-sections and lateral wings slid in the guide slots of the post channel. One spacer element keeps the bottom rail away from the base plate while a second spacer element separates the two rails from one another. The spacer elements have an outer face which is flush with the outer wall of the post having the channel into which the rail ends are inserted.

U.S. Pat. No. 5,161,783 discusses a fence rail and post connection which includes a hollow tubular PVC post with an opening formed in one vertical wall to receive a hollow tubular PVC fence rail. A hollow tubular PVC sleeve has flanges formed on the forward and rearward ends of the sleeve and is mounted within the post in alignment with the opening and the post wall. The sleeve is affixed within the post and a rail is then inserted through the opening and into the sleeve and affixed in position to form a rigid connection between the rail and post.

U.S. Pat. No. 6,017,019 discusses a modular railing including a plurality of upright posts and a plurality of composite hand rails extending between adjacent ones of the upright posts. The composite handrails each include a plastic outer shell and an internal metal reinforcing element extending longitudinally within the plastic shell. A plurality of lower rails extend between adjacent ones of the upright posts and a plurality of composite spindles extend between the lower rails and the handrails. A plurality of brackets couple the handrails and the lower rails with the upright posts. The brackets are adapted to be slipped over end portions of the handrails and over end portions of the lower rails and to be fastened to the upright posts. Preferably the brackets are made of metal and have a shaped opening matching a cross-sectional profile of the handrails to allow the brackets to be slipped over the end portions of the handrails. The brackets include flanges to allow the brackets to be fastened to the upright composite posts with fasteners. One of the handrails is oriented at an oblique angle relative to one of the upright posts and one of the brackets has an elongated shaped opening, relative to the other shaped openings in the other brackets, to receive the obliquely oriented handrail therein. U.S. Pat. Nos. 5,617,697 and 5,626,331 list the same inventor and discuss composite deck posts and composite spindles.

U.S. Pat. No. 5,853,167 discusses a decorative cover for posts which includes a collar portion which is configured to cover attachment devices and the like to provide a more aesthetically pleasing termination for the post. A cap portion can be provided which engages the collar to cover the end of the post. Preferably, the collar and cap portion can both be attached to the post without the use of tools.

U.S. Pat. No. 6,698,726 discusses a fence rail clip for attaching a fence rail to a vertical fence post. The rail clip has a bracket and a rail connector. The bracket may be secured to the vertical post. The rail connector has a rail receiving receptacle into which an end of a rail may be inserted and the connector is adapted to slidingly engage the bracket. When the position of the rail connector is altered by sliding the rail connector along the bracket, the angle of the rail receiving receptacle is altered, thereby changing the angle at which a rail may be attached to the post.

BRIEF SUMMARY OF THE INVENTION

As one aspect, novel brackets are provided for attaching a rail to a post. The brackets comprise a front face, first and second sides extending from the face, and first and second flanges. The first flange extends from the first side, and the second flange extends from the second side. The flanges are adapted for attaching the bracket to a post. The flanges can parallel or perpendicular to each other. When the flanges are perpendicular, the bracket can be fastened to a corner of a post. Novel brackets are provided for attaching a rail to a post at various angles. The brackets can include a bendable tab extending from the face, which provides additional versatility to the bracket, particularly as a means for attaching a stairway rail to a post.

As another aspect, railing assemblies for a deck or fence is provided. The railing assemblies comprise at least two vertical posts, one or more rails extending between the posts, and one or more brackets such as those described above. The rails have open ends, and the face and sides of the brackets are inserted or disposed within the open ends of the rails. The rails are fastened to the sides of the brackets, and the flanges of the brackets are fastened to the posts. Each of the brackets can have one or more bendable tabs extending from the face, and the rails may be fastened to the tab(s). When the rails are hollow and plastic, rail can be stiffeners can be disposed inside the rails. The rail stiffeners can be made with or modified to have tabs. As described below, such tabs can hook onto the brackets described herein to provide a railing assembly with excellent strength.

As yet another aspect, methods of building a railing assembly for a deck or fence are provided. The railing assembly has at least one rail attached to a post by fastening to one of the novel brackets described herein. The methods comprise the steps of erecting a vertical post, fastening a bracket to the vertical post, and fastening a rail to the bracket. Brackets such as those described above may be used. An escutcheon can be placed on the rail and attached to one or both of the post and the rail, so that the escutcheon covers a junction between the rail and the post. The brackets can be fastened to the face or corner of the post, and the bracket can be adapted to allow a horizontal or diagonal rail to meet the post at an angle. A tab on the bracket can be adjusted and the rail can be fastened to the tab. For example, the tab can be adjusted to reciprocate with an inside surface of the rail for a stairway.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective, partially exploded view of the use of a novel bracket to attach a rail to a post.

FIG. 2A is a view of one type of a novel bracket, and FIG. 2B illustrates a stairway rail and post in which the bracket of FIG. 2A is used to attach the rail to the post.

FIG. 3A is a view of another type of novel bracket, and FIG. 3B is a top view of a deck having rails attached to posts using the bracket of FIG. 3A.

FIGS. 4A and 4B are views of additional types of novel brackets. FIG. 4C is an illustrative top view of a railing system in which the bracket of FIG. 4A is used to fasten a rail to a post. FIG. 4D is an illustrative side view showing how the bracket of FIG. 4A can be fastened to a post.

FIGS. 5A through 5C show how a rail stiffener can be modified by cutting and removing a portion of each end and how the modified rail stiffener can be advantageously used with the novel brackets herein.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes novel brackets and railing assemblies for outdoor decks and fences. The present invention also includes methods of making such brackets and railing assemblies, including methods of building a railing assembly for a deck or fence, where the railing assembly includes a rail fastened to a post using one of the novel brackets described herein. The present invention also includes kits which comprise one or more novel brackets and optionally other deck or fence components for an outdoor deck or fence.

The brackets are generally used with rails having an open end which is to be fastened to a post, wherein the brackets are to be inserted into the open end. Rails made from synthetic materials such as plastics frequently have an open end, for example where the rails are a hollow shell of plastic or other synthetic materials. The brackets are particularly suited for use with synthetic deck and fence materials, including formable materials, extrudable materials, and manufacturable materials, and especially plastic materials. Examples of such materials include vinyls, polypropylenes, polyethylenes, PVCs, polycarbonates, acrylics, and other moldable materials. Another example of synthetic deck or fence material is roll-form aluminum rail. Other examples of synthetic deck or fence material are disclosed in U.S. Pat. Nos. 4,540,160; 4,809,955; 5,161,783; and 5,651,534.

The present brackets generally have a front face, first and second sides extending from the face, and first and second flanges. The first flange extends from the first side, and the second flange extends from the second side. The flanges are adapted for attaching the bracket to a post. The flanges can be parallel to each other and define a flange plane. The flanges can be substantially parallel to the face and substantially perpendicular to the sides. The flange plane can be at an angle with respect to the face, and the angle can be between about 20 and about 50 degrees. Alternatively, the flanges can be substantially perpendicular to each other.

The brackets can be made from any material having suitable strength and durability, including metals, plastics, and other synthetic materials. Preferably the brackets are made of metal and have a generally rectangular shape. (Rectangular means four-sided and includes a square shape unless otherwise noted.) Preferred materials for the bracket include metals such as aluminum, steel, copper, and other metals commonly used for building materials. The brackets include a front face, two sides extending from the face, and flanges extending from each of the sides. The sides generally extend toward a post, and the flanges are adapted for fastening the brackets to the posts with fasteners. The front face will usually be flat, and the face and sides can form an open box or channel. The brackets also include one or more tabs extending from the face. Preferably the bracket includes one tab that is free of (not connected to) the sides and is bendable to a desired position.

The brackets are adapted to fasten the rails to the posts so that the rails are held against movement. In this regard, the rails preferably are fastened to the bracket by means of screws, bolts, nails, adhesives or other fastening means which connect the rails to the sides of the bracket and preferably to the tab of the bracket as well. The brackets can have one or more holes in the sides adapted for receiving a fastener for fastening the rail to the bracket. The bracket may have one or more holes (usually two or three holes) in each flange adapted for receiving fasteners for fastening the bracket to the post.

In a railing assembly, it is desirable for the vertical posts and the horizontal rails to be securely attached in an aesthetically pleasing manner. It is also desirable for the components of the railing assembly to be designed for convenient installation and to be safe, reliable and economical.

As one aspect, a railing assembly is provided which includes a pair of vertical posts and at least one rail extending between the posts. The rails may be placed at a height so that they may act as handrails or may be diagonal so that they may act as stairway rails. The railing assembly may also include at least one lower rail extending between the posts. The railing assembly may also include a plurality of balusters extending between an upper rail and a bottom surface such as a floor or a lower rail. A plurality of brackets are used to attach the rails with the posts. The brackets are adapted to fit into end portions or openings of the upper rails and the lower rails and to be fastened to the upright posts. Decorative escutcheons can be used to cover the junction between the upper rails and the post and/or between the lower rail and the post.

This railing assembly with the novel brackets is easily manufactured and installed, is strong and sturdy, and is weather-resistant. The railing assembly has an excellent appearance and good strength (both in terms of bending resistance and compression load-carrying capability).

Referring now to the figures, FIG. 1 shows an exploded view of the components of a railing assembly comprising a post, bracket and rail. The railing assembly is assembled from individual components which are manufactured and sold as separate components and then can be assembled in the field by a professional installer or a home owner. The railing assembly includes an upright post 101. The post can be a post on an exterior deck or a fence post. A bracket 102 is shown which is to be fastened to the post 101 with a plurality of screws 103 or other fasteners. The bracket 102 includes a pair of flanges 104 through which the screws 103 are to be inserted. The bracket 102 shown in FIG. 1 has two holes 105 in each flange 104, though a greater or lesser number of holes may be provided. The holes can be pre-formed in the flange 104 by the manufacturer or drilled in the flange 104 by the end user.

A rail 106 having an open end is placed over the bracket 102. Preferably, the open end of the rail 106 and the size of the bracket 102 (in at lease one dimension) may be such that the rail 106 fits snugly over the bracket 102 and held in place (at least temporarily) by friction.

The rail 106 can be fastened to the bracket 102 by any suitable means, such as the screws 107 shown in FIG. 1. By using a screw 107 or another fastener on each side of the rail 106, the rail 106 can be fastened to the bracket 102. A decorative escutcheon 108 may be placed on the rail 106 so that it will cover the junction between the rail 106. The escutcheon 108 can be used to hide the flanges 104 and screws 107 and 103, thereby providing a more aesthetically pleasing appearance.

Extending between the upper rail and the lower rail can be a plurality of balusters or spindles. The balusters may be fitted into holes formed in the lower rails and holes formed in the underside of the upper rails. The baluster may be a plastic outer shell having a plain appearance or a decorative design. An elongate metal reinforcing element may be positioned within the baluster and extend from the upper rail to the lower rail. However, it is not required to use a reinforcing element or a decorative design; any suitable baluster or spindle may be used.

The rails (particularly the upper rails) may be rectangular or another shape. The rails may include decorative features. Lower rails are frequently simple rectangular elements, but they also may have a decorative shape and/or features. It will be appreciated by those skilled in the art that the profiles of the handrails and the lower rails can be modified as desired. Moreover, the rails can be composite units having a plastic outer shell and a metal reinforcing element placed therewithin. The rails may each include a plastic outer shell and an internal metal reinforcement element extending longitudinally within the plastic shell. Such reinforced rails are especially desirable as the upper rail, to serve a protective purpose. On the other hand, the lower rails typically are not reinforced, although it may be desirable in some circumstances to provide reinforced lower rails.

To keep moisture and debris out of a hollow post, it may be desirable to cover the open end of the post with a cap. For example, a decorative and/or functional cap may be placed atop the posts.

Each of the brackets includes left and right flanges which are provided to be placed flat against one of the side faces of the posts for mounting thereto. In this regard, the flanges each include mounting holes 105 for receiving screws or bolts or rivets there through for fastening the mounting bracket to the upright post.

Escutcheons (or covers) 108 form a box-like enclosure for covering the junction of the rails and the post. The use of escutcheons 108 is facilitated by the present brackets, in that the brackets fit inside the open end of the rail instead of surrounding its exterior. As a result, the brackets do not provide extra height or width around the rail at its junction to the post. The flanges are of the bracket are easily covers by such escutcheons. The escutcheons 108 will usually be glued into place or fastened by other suitable means for fastening, such as screws, nails, clips or the like.

The present brackets provide yet another advantage when they are used with reinforced rails, in that a rail stiffener can cooperate with the bracket to form a strong and secure rail assembly. In FIG. 1, rail 106 has a rail stiffener extending through its interior. The rail stiffener inside the rail 106 is almost entirely hidden from view in FIG. 1, but metal tabs 109 on the ends of the rail stiffener can be seen. (Rail stiffeners are also shown in FIGS. 5A through 5C where the same metal tabs 109 are shown as tabs 504 and 505.) FIG. 1 illustrates generally how a metal tab 109 on a rail stiffener can cooperate with bracket 104 in a railing assembly. Tab 109 can be bent downward so that it can hook into the opening at the top of the bracket 104. By hooking the rail stiffener to the bracket 104, the rail stiffener and rail are fastened to the post, and the weight-bearing capacity of the rail is greatly increased. The railing assembly which is assembled in this manner has excellent strength (both in terms of bending resistance and compression load-carrying capacity).

The brackets can be made of metal such as aluminum, stainless steel, galvanized steel or copper. Typically, the brackets are made from sheet metal which is stamped and bent into shape. For example, the brackets can be made of flat aluminum stock which is formed into shape. Brackets stamped or cut from sheet metal are preferred due to their unitary nature. A unitary bracket is formed as one piece rather than assembled from multiple pieces. Suitable brackets are made from aluminum stock having a thickness in the range of from 0.05 inch to 0.075 inch, alternatively a thickness of about 0.06 inch, alternatively a nominal thickness of 0.0625 inch. Because the brackets are not in view when in use, they need not be colored or treated to change their appearance. The corners of the bracket may be chamfered or dulled to reduce their sharpness.

FIG. 2A provides a closer view of a bracket 201. This bracket 201 is adapted for fastening to one side of a post (for example, as illustrated in FIG. 1). The bracket 201 has a front face 202 that is substantially rectangular and flat. The bracket 201 has two perpendicular sides (only one perpendicular side 203 being visible in FIG. 2A). Each of the perpendicular sides leads into a flange 204 which is itself perpendicular to the side 203 but parallel to the face 202. Each flange 204 has one or more holes 205 through which a screw or other fastener can be inserted to fasten the bracket 201 to a post.

The bracket shown in FIG. 2A includes a tab 206 extending from the face 202. The tab 206 may be connected to the sides 203 but preferably is not connected to (is free of) the sides 203, which can have the advantage of making the bracket easier to manufacture. The entire bracket can be cut or stamped from a single sheet of metal and then bent into the configuration desired. If the tab 206 is to be connected to the sides 203, an additional connecting step, such as soldering, may be used in the manufacturer of the bracket.

The tab 206 can provide a substantial advantage in the ability of the bracket to securely attach a rail. The tab 206 provides an additional area of contact between the rail and the bracket, and an additional screw or other fastener may be inserted through the rail and the bracket together. Thus, the bracket having a tab and two sides has three areas of contact with a rail and fasteners, and the rail can be fastened to the bracket from three directions. When the bracket has two tabs, the rail can be fastened to the bracket from four directions with four fasteners.

The tab 206 also provides an advantage in the ability of the bracket to attach a stairway rail to a post. In such an embodiment, the tab 206 is adjustable (as shown in FIG. 2B) such that it may be bent into an upward, angled position with manual effort. However, the tab should have sufficient resistance so that it does not bend out of the desired position too easily. For example, a bracket in the shape of FIG. 2A made from aluminum having a thickness of about 0.06 inch has a tab with an acceptable combination of flexibility and strength.

FIG. 2B shows how the bracket 201 of FIG. 2A may be used to attach a diagonal rail for on a stairway 207. The bracket 201 has been fastened to a post 208 with two screws in each flange. The stairway rail 207 has a part of open and angled ends 209, with the ends having the angles desired for the angle of the stairway, which is typically about 45 degrees. The angled end 209 of the stairway rail 207 will be flush with the face of the post 208 when the rail is in place, as shown in FIG. 2B. The stairway rail 207 can be fastened to the bracket 202 by one or more fasteners 210. The fastener 210 may be a screw, bolt or nail through the rail 207 and tab 206. Alternatively or additionally, the fastener may be adhesive between the inside of the rail 207 and the tab 206. Furthermore, fasteners may be used on the sides of the bracket and rail, as shown in FIG. 1. In this embodiment, the length of the bracket 201 (the longer dimension of the face 202) is shorter than the open length of the open end 209, so that the bracket 201 will fit inside the open end 209.

Brackets can be made with any suitable dimensions. Bracket 201 preferably has a length of from about 2 inches to about 4 inches, more preferably about 3 inches. The face preferably has the length of the bracket and has a width of from 1.5 to about 3 inches, more preferably about 1.7 or 1.75 inches. The sides preferably have the length of the bracket and a height of from 0.75 to 1.25 inches, more preferably about 0.9 or 1 inches, most preferably about 0.94 inch. The flanges also preferably have the length of the bracket and a width of from about 0.5 to about 1 inch, more preferably about 0.67 or 0.75 inch. The tab preferably has a width which is the same as smaller than the width of the face and a height that is the same as or smaller than the height of the sides. More preferably, the tab has a width of from about 1 inch to about 3 inches, more preferably from about 1.3 to about 1.5 inches, and a height a height of from 0.75 to 1.25 inches, more preferably about 0.9 or 1 inches, most preferably about 0.94 inch.

For example, a bracket 201 can have a nominal length of 3.06 inches (3.19 inches when including the bend leading to the tab 206), a face 202 with a nominal length of 3.06 inches and a nominal width of 1.70 or 1.75 inches, sides 203 with nominal height of 0.94 inches, flanges 204 with a nominal width of 0.67 or 0.75 inch, and a tab 206 with a nominal height of 0.94 inch and a nominal width of 1.33 inches. As is evident from the foregoing dimensions, small gaps (less than 0.1 inch, for example about 0.06 inch) can be provided between the sides of the tab 206 and the sides 203 of the bracket. Such gaps permit the tab to be moved between the sides 203 without contacting them.

The intersections of the face with the sides will form face-side angles and the intersections of the sides with the flanges will form side-flange angles. The face-side angles are generally considered from the interior of the bracket, and the side-flange angles are generally considered from the exterior of the bracket. By considering the angles from those perspectives, the face-side angles and the side-flange angles will be less than 180 degrees. (If considered from the opposite perspective, the angles would be more than 180 degrees). The face-side angles and the side-flange angles can be substantially perpendicular, or may have another suitable angle as described below.

In a similar fashion, a bracket 201 may be used at the bottom of the stairway rail 207, with the difference that the tab will be oriented toward the bottom rather than the top, so that the tab 206 will be reciprocal to the inside of the top of the rail 207.

A bracket 201 can have a tab 206 at both ends or can have a tab at one end and an opening at the other end. An opening may be desired at the top of a bracket fastened to a post. For example, an opening is desired if one wishes to hook the tab 109 of the rail stiffener to a bracket 104 as described above and generally shown in FIG. 1. An opening can be provided by manufacturing a bracket that has an open end rather than a tab, or by moving tab 206 out of the opening, such as by bending it inward or outward or by cutting the tab 206 off the bracket 201.

Another aspect of the novel brackets disclosed herein relates to the angles formed by the face and the sides. For example, the bracket 201 can be adjusted or manufactured so that the angle between the flat face 202 and one or both sides 203 is about 90 degrees. Alternatively, the bracket 201 can be adjusted or manufactured so that the angle is more or less than about 90 degrees. Preferably, the angles formed by the interior of the flat face 202 and each of sides 203 is slightly greater than 90 degrees, for example about 90.5 degrees, about 91 degrees, or about 91.5 degrees. Preferably the angle is greater than 90 degrees but less than about 115 degrees, 110 degrees, 105 degrees, 100 degrees, 99 degrees, 98 degrees, 97 degrees, 96 degrees, 95 degrees, 94 degrees, 93 degrees, or 92 degrees. By providing an angle slightly greater than 90 degrees, the bracket's width slightly increases from the face to the back (at or near the flanges). This provides an advantage for the insertion of the bracket into the rail and subsequent fastening. The bracket will initially fit easily into the opening but then will fit snugly in the opening after the bracket is pushed into the opening. The bracket will fit snugly since the wider base will contact and apply pressure to the interior of the rail. In this respect, the bracket may be fastened (at least partially) to the rail by friction or by the bracket acting as a leaf spring inside the rail. The angle formed by the interior of the flat face 202 and each of sides 203 is slightly greater than 90 degrees when it is still capable of being inserted into the opening of a rail.

FIG. 3A shows an alternative embodiment of a bracket which is adapted for securely attaching a horizontal rail so that it meets a face of a vertical post at an angle. The bracket 301 of FIG. 3A comprises a face 302, two sides 303, and two flanges 304. The flanges 304 are not parallel with the face 302, but rather form an angle of approximately 22 degrees with the face 302. As a result, the bracket is suitable for attaching a rail at an angle of approximately 22.5 degrees. Preferred angles for the rail meeting the face of a post are from about 20 degrees to about 50 degrees, alternatively about 22.5 degrees or about 45 degrees. Although not shown with a tab, bracket 301 may include one or more tabs as described above. FIG. 3B illustrates how rails 309 may engage the face of posts 308 at an angle. Such an arrangement may be desirable for a deck (or portion of a deck) that has a shape other than square, for example, a hexagon shape or octagon shape. FIG. 3B provides a top view of a hexagonal deck, and the rails 309 are attached at an angle to posts 308. The ends of the rails 309 can be cut or otherwise adjusted to the desired angle, so that the edges of the rail opening will be flush with the face of the post 308. For the bracket of FIG. 3A, it will be desirable to cut a V-shape in the end of the rail, so that the end of the rail will be reciprocal to the corner of the post.

In this type of bracket, the face-side angles can be substantially perpendicular, or may have another suitable angle as described above. The side-flange angles will differ in this type of bracket and will not be perpendicular. The two side-flange angles of this type of bracket will usually be supplementary angles (meaning that the sum of their degree measurements equals 180 degrees). For example, the two side-angles can be about 67.5 degrees and about 112.5 degrees, or the two side-angles can be about 45 degrees and about 135 degrees, or the two-sides can be another pair of supplementary angles.

Brackets of this type can also be made with any suitable dimensions, and bracket 301 generally shares the preferred dimensions set forth above for bracket 201. It is contemplated that the height of one of the sides of bracket 301 will be shorter than the other side. The side with the smaller side-flange angle will generally be shorter than the other side. If a tab is present, it will usually have a height which is the same as or shorter than the height of the shorter side of bracket 301.

As depicted in FIG. 1, construction of a railing assembly according to the present invention allows ready assembly and construction of the railing at the building site. In particular, one would install the posts a fixed distance apart and then install brackets at appropriate positions on the post. Then one would cut the rails to length to match the spacing of the posts from one another. One would then install balusters in openings formed in the upper and lower rails and place brackets on the end of the rails. The rails are then lifted into position between the posts and the fastened to the brackets and thereby fastened to the posts with threaded fasteners. This allows for a quick, easy, and precise assembly and construction of a railing. Such a railing has ready application indoors (such as for use with a balcony) or outdoors (as a railing for a deck or as fencing).

FIGS. 4A and 4B show additional embodiments of the novel brackets. FIGS. 4A and 4B show brackets adapted for connecting a rail to a corner of a post. Each of the brackets comprises a face, two sides extending from the face, and two flanges. The sides are substantially perpendicular (or have an angle slightly greater than 90 degrees), and each side lead into a flange which is not perpendicular to the side. Instead, the side-flange angles for this type of bracket are obtuse angles (90 degrees to 180 degrees), and the sum of the two side-flange angles will be about 270 degrees; this makes the brackets suitable for attachment to a corner of a post by attaching one flange to one face of the post and the other flange to a separate but adjoining face of the same post.

FIG. 4A shows a bracket 401 having a face 402, two sides 403 extending from the face 402, and two flanges 404 extending from the sides 403. Each flange 404 has one or more holes 405 through which a screw or other fastener can be inserted to fasten the bracket 401 to a post. The flanges 404 are substantially perpendicular to each other, in contrast to the planar flanges of the brackets shown in FIGS. 2A and 3A. The perpendicular relationship of the flanges allows the bracket to be attached to a corner of a post by fastening the flanges to adjacent faces of a rectangular (or square) post. The lengths of the sides 403 and the side-flange angles will determine the angle at which the rail will be attached to the post. For example, the bracket shown in FIG. 4A will permit the rail to meet the post at an angle of approximately 45 degrees because both flanges 404 makes a 135 degree angle (90 degrees plus 45 degrees) with sides 403, and the sides 403 are the same height.

FIG. 4B shows a bracket 401b having a face 402b, two sides 403b extending from the face 402b, and two flanges 404b extending from the sides 403b. Each flange 404b has one or more holes 405b through which a screw or other fastener can be inserted to fasten the bracket 401b to a post. The flanges 404b are substantially perpendicular to each other, so that the bracket is adapted to be attached to a corner of a post. The lengths of the sides 403b can be different, and the lengths of the sides and side-flange angles will cooperate to determine the angle at which the rail will be attached to the post using this bracket. For example, the bracket shown in FIG. 4B will permit the rail to meet the post at an angle of approximately 22.5 degrees (which includes a nominal measurement of 21.5 degrees) because flange 404b (facing outward in FIG. 4B) makes a 112.5 degree angle (90 degrees plus 22.5 degrees) with side 403b and the other flange (facing inside FIG. 4B) makes an angle of 157.5 degrees with the other (shorter side). The longer side (facing outward in FIG. 4B) has a height of about 1.875 inches, which the shorter side (facing inside FIG. 4B) has a height of about 1.25 inches. As another example, another bracket for connecting a rail to a post at an angle of approximately 45 degrees can have sides 403b of different heights. The side-flange angles are both 135 degrees, but one side has a height of about 2.5 inches while the other side has a height of about 1.25 inches. The ends of the rails can be cut or otherwise adjusted to the desired angle, so that the edges of the rail opening will be flush with the face of the post. This bracket is suitable for attaching a rail having an end cut to an angle of 45 degrees. Preferred angles for the rail meeting the face of a post are from about 20 degrees to about 50 degrees, alternatively about 22.5 degrees or about 45 degrees. The brackets shown in FIGS. 4A and 4B can include one or more tabs.

FIGS. 4C and 4D show how the bracket of FIG. 4B can be used to fasten a rail to a post. FIG. 4C is a view from the top which shows how the bracket 401 is attached to the corner of a post 408 and fits inside the rail 407. FIG. 4D shows how the bracket of FIG. 4B can be attached to a corner of a post 408 using four screws (though other suitable fasteners may be substituted). Although the use of a bracket for an attachment angle of about 45 degrees is shown, brackets can be made to accommodate any angle desired.

Brackets of this type can also be made with any suitable dimensions, and brackets 401 and 401b generally share the preferred dimensions set forth above for bracket 201. As mentioned above, it is contemplated that the height of one of the sides of bracket 401b will be shorter than the other side. However, in contrast to bracket 301, the side of bracket 401b with the larger side-flange angle will generally be shorter than the other side. The brackets shown in FIGS. 4A and 4B can include one or more tabs. If a tab is present, it will usually have a height which is the same as or shorter than the height of the sides of the bracket 401 or the shorter side of bracket 401b.

The novel brackets described herein can be used with rails of various sizes. Typical sizes of rails include 2 inches by 3.5 inches; 1.75 inches by 3.5 inches; 1.75 inches by 3 inches; and 2 inches by 6 inches. Brackets can be designed and made to accommodate rails of any of these sizes or other sizes. By way of example (but not as a limitation), a bracket with a face measuring about 1.75 inches by about 3 inches is contemplated for use with a 2 by 3.5 inch rail as well as a 2 by 6 inch rail. Such a bracket will fit snugly inside the open end of such a rail. The open end of the rail is generally slightly smaller than the stated size of the rail, since the walls of the rail have some thickness.

The brackets are shown herein with rectangular rails, but it is recognized that the brackets can be employed with rails having a non-rectangular external shape and/or decorative features. For example, a decorative rail may be manufactured having a square, circular, triangular or another shape other than rectangular, and may include decorative features such curves, ribs, fluting, and others. Rails may have various external shapes and decorative features while having an opening at the end which can receive a bracket. For example, a rail having an external shape other than rectangular and decorative features may having a opening that is sized and shaped to accommodate a bracket. Preferably, the rail defines a rectangular opening adapted to receive a bracket. Thus, the novel brackets described herein have a great deal of versatility and compatibility with rails and posts made by different manufacturers.

As mentioned in connection with FIG. 1, it may be desirable to reinforce rails (especially upper rails) with a rail stiffener. For example, rails may be composite constructions including an outer plastic shell, and an internal reinforcing means (a rail stiffener). The rail stiffener is generally at least partially rectangular and fits within a hollow rail. The rail stiffener can have open ends and may include a means for connecting the rail stiffener to a post or bracket. The rail stiffener runs longitudinally within the rail shell and is usually about the same length (though it may be slightly shorter to leave room for the bracket inside the rail at each end).

The rail stiffener can be any material of suitable strength, durability and stiffness, for example sheet metals such as aluminum, stainless steel, galvanized steel or copper. Rail stiffeners made of G-90 galvanized steel with a wall thickness of about 0.100 inches are suitable. The rail stiffener can be made by folding a sheet of metal and is sized and adapted to be closely fitted within the interior of a hollow plastic shell. In this regard, there can be a generally open side of the rail stiffener. This construction allows the rail stiffener to be economically manufactured by bending or otherwise forming flat sheet stock into the desired shape.

FIG. 5 shows how a commercially available rail stiffener can be modified for use with the novel brackets described herein. Rail stiffeners are commonly used with rails made from plastic materials such as extruded vinyl. Rail stiffeners provide increased stiffness, strength or stability to a rail. Typically, a rail stiffener fits inside a hollow rail, though other arrangements of a rail and rail stiffener may be suitable. The rail stiffener typically extends through the rail and between two posts to which the rail stiffener is fastened, either directly or using a fastening device. The rail stiffener may fit snugly inside the rail and/or the rail may be in contact with and supported by the top of the rail stiffener. Many commercially available rail stiffeners are made of metal. They are often used with an upper plastic rail to increase the force which the upper rail can comfortably withstand. Commercially available rail stiffeners include A-type, C-type and P-type stiffeners, all of which have a top wall or face.

An example of a commercially available P-type rail stiffener (and how it may be modified) is shown in FIG. 5A. The stiffener 501 is made of metal and has an upper box portion 502 and a lower flange portion 503. From one side it looks like a “P”, which gives it the P-type name. The width of the upper box 502 is slightly smaller or about the same as the width of a rail opening, and the height of the stiffener 501 (which is the sum of the height of the upper box 502 and the height of the lower flange 503) is slightly smaller than or about the same as the height of the rail opening. The rail stiffener and rail are typically fabricated or cut to a desired length. Most commercially available rail stiffeners can be cut using tools commonly available at a construction site.

FIGS. 5A through 5C show how a commercially available rail stiffener can be modified by cutting and removing a portion of each end. As illustrated in FIG. 5A, a relatively small portion 506 and 507 is removed from each end. The portion 506 and 507 is made by cutting the lower flange 503 and three (3) sides of the upper box 502 is not cut from the rest of the stiffener 501. The vertical sides of the cut portion 506 and 507 are cut from the top side, so that the cut portions 506 and 507 are removable from the rail stiffener 501. By cutting and removing the small portions 506 and 507, bendable tabs 504 and 505 are made.

It is also contemplated that kits may be provided which include one or more of the brackets described above. For example, a bracket kit may comprise a plurality of brackets shown in FIG. 2A and a plurality (most likely a lesser number) of brackets for angled attachment (for example, one or more of the brackets shown in FIGS. 3A, 4A, and/or 4B). A railing assembly kit may comprise one or more brackets and other components for building an outdoor deck or fence, including but not limited to rails, rail stiffeners, posts, escutcheons, balusters, and/or flooring.

All patents and other documents cited herein are fully incorporated by reference to the extent such disclosure is not inconsistent with this invention and for all jurisdictions in which such incorporation is permitted.

While the present invention has been described and illustrated by reference to particular embodiments, it will be appreciated by those skilled in the art that the invention lends itself to many different variations not illustrated herein. For these reasons, then, reference should be made solely to the appended claims for purposes of determining the scope of the present invention.

Although the appendant claims have single appendencies in accordance with U.S. patent practice, each of the features in any of the appendant claims can be combined with each of the features of other appendant claims or the main claim.

Claims

1. A bracket for attaching a rail to a post, the bracket comprising a front face; first and second sides extending from the face; first and second flanges adapted for attaching the bracket to a post; wherein the first flange extends from the first side, and the second flange extends from the second side.

2. The bracket of claim 1 further comprising a bendable tab extending from the face, and the tab is free of the two sides.

3. The bracket of claim 1 wherein the flanges are parallel to each other and define a flange plane.

4. The bracket of claim 3 wherein the flanges are substantially parallel to the face and substantially perpendicular to the sides.

5. The bracket of claim 3 wherein the flange plane is at an angle with respect to the face, and the angle is between about 20 and about 50 degrees.

6. The bracket of claim 1 wherein the flanges are substantially perpendicular to each other.

7. The bracket of claim 1 wherein intersections of the face with the sides defines face-side angles, and the face-side angles are slightly greater than 90 degrees.

8. The bracket of claim 1 wherein intersections of the sides with the flanges define side-flange angles, and the sum of the side-flange angles is about 180 degrees or about 270 degrees.

9. A railing assembly for a deck or fence comprising:

at least two vertical posts;

one or more rails extending between the posts, the rails having open ends;

a plurality of brackets, each of the brackets comprising a front face; first and second sides extending from the face; first and second flanges adapted for attaching the bracket to a post; wherein the first flange extends from the first side, and the second flange extends from the second side;

wherein the face and sides of the brackets are within the open ends of the rails;

wherein the rails are fastened to the sides of the brackets; and

wherein the flanges of the brackets are fastened to the posts.

10. The railing assembly of claim 9, wherein the railing assembly is a stairway railing.

11. The railing assembly of claim 9, wherein each of the brackets further comprises a bendable tab extending from the face, and the rails are fastened to the tabs.

12. The railing assembly of claim 9, wherein at least one of the brackets comprises flanges which are at an angle with respect to the face, and the angle is between about 20 and about 50 degrees.

13. The railing assembly of claim 9, wherein at least one of the brackets has flanges substantially perpendicular to each other and is attached to a corner of one of the posts.

14. The railing assembly of claim 9, wherein the rails are hollow and plastic, and rail stiffeners are disposed inside the rails, the rail stiffeners having tabs adapted for hooking onto the brackets.

15. A method of building a railing assembly for a deck or fence having at least one rail attached to a post, the method comprising the steps of:

erecting a vertical post;

fastening a bracket to the vertical post, wherein the bracket comprises a face, two sides extending from the face, and a flange extending from each of the sides; and

fastening a rail to the bracket.

16. The method of claim 15, further comprising placing an escutcheon on the rail and attaching the escutcheon to one or both of the post and the rail, such that the escutcheon covers a junction between the rail and the post.

17. The method of claim 15, further comprising fastening the bracket at a corner of the post.

18. The method of claim 15, further comprising the steps of adjusting a tab on the bracket and fastening the rail to the tab.

19. The method of claim 18, wherein the tab is adjusted to reciprocate with an inside surface of the rail for a stairway.

20. The method of claim 15, wherein the rail meets a face of the post at an angle.