Post and railing construction
A post and railing construction permits construction of fences and railings from parts which are pre-molded from a resinous material such as rigid polyvinyl chloride (PVC). The parts require no painting and are not prone to corrosion or rust when exposed to harsh environments. The posts have a rigid upright core element with a hollow shell mounted on the core element by one or more frames. In one embodiment of the invention, railings are supported on brackets mounted on the frames of the posts. In another embodiment of the invention, railings are supported directly on the frames of the posts by routed openings in the hollow shell. The present invention also provides an easy to assemble fence assembly having the appearance and style of a picket fence. Exterior fasteners may be covered with optional caps to avoid direct exposure to damaging elements, such as moisture.
This application is a divisional application of U.S. patent application Ser. No. 10/632,778, filed Aug. 1, 2003, which claims the benefit of the filing date of U.S. Provisional Application No. 60/400,294, filed Aug. 1, 2002, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTIONThe present invention relates to post and railing assemblies, and more specifically to post and railing assemblies with standard prefabricated parts.
BACKGROUND OF THE INVENTIONPost and railing fences have traditionally been constructed using a variety of timber, including pine and cedar. Although timber is a reasonably sturdy material, timber wears down over time, yielding to extreme weather conditions, prolonged rotting, termite infestation, and other factors. Even treated timber can experience rotting and warping. The development of polyvinylchloride (PVC) and other plastics has led to the use of plastics in post and railing assemblies. Although plastic railing materials are more durable than timber in many respects, known plastic railing systems have some drawbacks. For example, some plastic systems include a large number of fasteners and parts that make installation difficult and costly. In addition, many plastic railing systems include visible fasteners and seams that detract from the appearance of the railing system. The components in some plastic railing systems do not permit reliable or secure connections between components. Based on these drawbacks, there is a clear need for plastic railing systems that are economical to install, aesthetically pleasing, and securely constructed.
SUMMARY OF THE INVENTIONA post and railing construction in accordance with the present invention permits construction of fences and railings from parts which are pre-molded from a resinous material such as rigid polyvinyl chloride (PVC). The parts require no painting and are not prone to corrosion or rust when exposed to harsh environments. In addition, the parts are configured to be used on a number of different railing and fence assemblies.
In one embodiment of the invention, railings are supported on brackets mounted on posts. In another embodiment of the invention, railings are supported directly on the posts by routed openings in the posts. The present invention also provides an easy to assemble fence assembly having the appearance and style of a picket fence. Metal components that are used in the invention may be covered to avoid direct exposure to damaging elements, such as moisture. For example, the railing construction may be provided with covers that are placed over screws to protect the screws and hide them from view.
Posts are provided having a uniform square or rectangular flat-sided structure. The posts are formed of a tubular shell, preferably having a square or rectangular internal surface similar to the exterior surface. The shell has a relatively thin rigid wall and may be reinforced along its length by a plurality of internal frames. The frames are configured to engage the internal surfaces of the shell and slide along a central cylindrical core such as a pipe, which may be made of tubular steel or other strong material.
In erecting the posts, the core is solidly connected to the ground, a floor, a deck or other base structure. This can be done by conventional means by embedding the core pipe in concrete or other solid material, or by mounting the core pipe to a base with brackets and/or fasteners. A simple cap, such as a pyramidal closure or other decorative shaped cover may be attached to the top of the shell. The cap may snap on and slide off of the shell, and be interchanged with different cap configurations to modify the appearance of the assembly. The support frames are slidable along the length of the core pipe to allow adjustment of the frames to a desired height. One frame member may be positioned at the top of the pipe and one frame positioned at the bottom of the pipe. Once the frames are adjusted to the proper positions, the frames may be secured to the pipe. The outside of the frame means may either provide a conforming pattern to the internal cross-section of the shell or sufficient contact points with the shell to keep the shell oriented in a predetermined position once that position has been selected and the frames anchored to the post. Anchoring can be accomplished in a variety of ways, such as by using bolts. The frames may be formed in two pieces that are connected around the core pipe in a clamp-like arrangement. Initially, the two frame pieces may be bolted together loosely to allow the assembled frame to be axially adjusted on the pipe and placed in proper position. Once the frame pieces are properly positioned, the bolts may be tightened to stabilize the frame in frictional engagement with the pipe.
The railing can be assembled by measuring the desired distance between posts and erecting the core pipes at desired locations. The lower frames are then positioned on the posts, and the shell is placed over the frames. Once the orientation of the shell is properly set, the lower frame is tightened in place. Upper frames may then be attached to the post and aligned based on the orientation of the lower frame and the shell. Once the upper frame is in proper position, it is tightened to the core pipe, similar to the lower frame. After the shell is installed over the frames, brackets may be anchored to the shell and frames with fasteners. In addition to anchoring the shell on the core pipes, the brackets are configured to support rails between posts.
When screws are used with brackets, the screws are placed in cylindrical openings in the brackets. A narrow shoulder may be provided on the interior of the openings at the inner most end. The cylindrical openings may be hidden or made less apparent by covers. The covers may be formed of resinous material and have a generally cup-shaped structure with cylindrical sidewalls. The sidewalls may be configured to fit snugly within the cylindrical openings. An end of each cover may conform to the exterior contours on the bracket to hide or minimize notice of the screw hole and cover.
In a second embodiment, railings are secured directly to posts through routed or punched openings that conform to the geometry of the rails. The rails assist in securing the shells in place on the posts. The rigid railing or fence panel arrays extend through the holes and are anchored between frames secured to the core to limit displacement of the shell.
In a third embodiment, a picket fence assembly is provided. A special resilient cleat made of resinous material attached at one end to horizontal fence or railing members is designed to fit within a tubular picket at a conforming hole. The cleat has a cam surface which acts as a latch to mount the picket to the rail. A number of cleats may be coupled with the rails to provide latching arrangements between the rails and a series of pickets.
BRIEF DESCRIPTION OF THE DRAWINGSThe embodiments of the present invention may be better understood by reference to the accompanying drawings, in which:
Referring first to
The external brackets are used to connect each railing array to a post 20. The brackets may be attached to the post by bolts, or other conventional means, as will appear hereafter. In
Referring now to
The support brackets 32 and 34 are configured to mount on a side face of a post, as discussed above. In particular, brackets 32 and 34 are designed to fit on flat surfaces of a standard post shell 20a. Bracket 32 is shown in more detail in
The design of the vertical shells 20a is intended to produce high strength supports having a uniform appearance. Each post 20 has a high strength structural core 36 which may be formed of a variety of structural materials. For instance, the core 36 may be formed out of cylindrical steel pipe. The core 36 is configured to support one or more frames that may be mounted on the core to anchor the shells 20a to the core. The cores 36 may be supported in any conventional manner. For example, the cores 36 may be embedded in a concrete floor or deck. Alternatively, the cores 36 may be supported by attaching them through brackets to a wooden deck or floor which accepts screws or bolts to anchor the cores in place. The hollow, vinyl shell 20a may have a square cross-section, but can also be made in other shapes if desired. Whatever the shape, it is desirable to have a hollow inner surface that is uniform in its cross-section. The dimensions of the shell are otherwise determined by the scale of the actual fence or railing being supported. The space between the shell 20a and the core 36 may be bridged by a plurality of structured support frames.
Referring to
As seen in
It is noted that the frames are securely mounted on the upright core 36 to provide a firm lateral support for the shell 20a. The positions of the frames 38 in registry with the upper and lower rails 26 and 28 enables the brackets to be firmly supported by the core 36 and the frames 38 and to provide secure vertical support for the rails 26 and 28.
In some cases, it may be desirable to have one solid support frame along the length of the core. Referring to
The tubular section 340 of the support frame 338 preferably contacts the exterior of the core 336 in a tight frictional engagement. The frictional engagement provides resistance against rotation so that the frame can be set to the proper orientation on the core and resist further rotation from incidental bumps during installation. Frictional engagement may be provided in a number of ways. For example, the inner diameter of the tubular section may be substantially equal to the outer diameter of the core 336 so as to form a snug connection. Alternatively, the inner diameter of the tubular section 340 may include one or more longitudinal ribs 346, as shown in
A corner flange 343 extends from the outward end of each support fin 342. The corner flanges 343 are configured to engage the inner wall of the shell 320 and provide a backing surface for mounting support brackets to the shell with one or more fasteners. In
The interior wall dimensions of the shell 320 are slightly larger that the exterior dimensions of the support frame, providing a clearance space between the support frame 338 and shell. Preferably, the support frame 338 includes gaskets or friction elements 352 on the edges of the corner flanges. The friction elements are configured to extend through the clearance space and frictionally engage the interior of the shell 320 so that the shell fits snugly around the support frame. In this arrangement, the frictional engagement reduces the potential for rattling or incidental shifting of the shell around the support frame. The friction elements 352 may be formed of rubber or other flexible material. In addition, the friction elements 352 may be connected with the corner flanges by an extrusion process, an adhesive, or other technique.
Referring to
The support frame 338 may be installed as follows. After the core 336 is mounted to a base support, the support frame 338 is held over the core with the tubular section 340 aligned with the core. The support frame 338 is then lowered over the core and advanced down the core until the support frame is placed at the desired position on the core. Once in the desired position on the core, the support frame is rotated to the desired orientation corresponding to the desired orientation of the shell. At this time, a screw or other fastener may be inserted through the tubular section 340 and into the core 336 to fix the orientation of the support frame. The shell 320 is then slid down over the support frame 338 with the inner walls of the shell in alignment with the corner flanges 343 on the support frame. If desired, a channel member 350 may be inserted into the interior of the shell on the side where brackets will be mounted. The channel member 350 is inserted through the open top end of the shell and advanced downwardly into the shell between two of the support fins on the support frame. The top end of the post structure may then be closed with a cap to enclose and conceal the interior components of the post.
Referring to
Referring to
The exterior of the brackets 22, 24, 32, 34, 74 and 84 have a curved surface 53 surrounding the cylindrical holes 54. The surface 53 exhibits a compound curvature. For manufacturing economies, the curved surfaces 53 around every cylindrical hole 54 on each bracket have the same configuration, which conforms with the curvature of the surface of the end walls 56b of the covers 56. Thus, any cover 56 may be used with any one of the brackets to provide a substantially smooth and aesthetically pleasing appearance to the assembly.
Referring now to
Routed opening 122 is configured to conform to the shape of the handrail 126, and routed opening 124 is generally rectangular to accommodate the respective cross-sectional shape of bottom rail 128. Referring to
Referring now to
In a preferred arrangement, individual pickets 64 are attached to both the top and bottom rails 59 using a spring cleat 60 cast from resilient polymeric resin. The cleat 60 has a simple configuration, as seen in
The pickets 64 may be installed after the rails 59 are connected between adjacent posts 220. Alternatively, the pickets may be pre-assembled to rails to form a panel or array which is installed as a unit between posts. Cleats 60 are attached to the upper and lower rails 59 at incremental spacings corresponding to the desired spacing between individual pickets 64. Referring to
The terms and expressions which have been employed are used as terms of description and not of limitation. There is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof. It is recognized, therefore, that various modifications are possible within the scope and spirit of the invention. Accordingly, the invention incorporates variations that fall within the scope of the following claims.
Claims
1. A bracket for coupling a railing member to a supporting structure, said supporting structure having a perimeter contour, said bracket comprising a socket end adapted to receive an end of the railing member and a mounting end for connection to the perimeter contour of the supporting structure, said bracket comprising at least one non-planar surface for visually blending the connection between the bracket and the support structure.
2. The bracket of claim 1 comprising a railing inserted through the socket end for connection with a post and railing assembly, said railing having an outer wall that engages the socket end in a friction fit.
3. The bracket of claim 2 comprising a plurality of resilient flexible spring sheets in the socket end in frictional engagement with the outer wall of the railing, each spring sheet having a fixed end connected substantially adjacent to the socket end and a cantilevered portion extending from the fixed end toward the mounting end of the bracket.
4. The bracket of claim 1 comprising a rear face contour on the mounting end of the bracket, wherein the rear face contour and the perimeter contour on the supporting structure have substantially identical non-planar geometries for visually blending the connection between the bracket and the support structure.
5. The bracket of claim 4, wherein the perimeter contour of the supporting structure has a convex curvature and the rear face contour of the bracket has a concave curvature substantially identical to the curvature of the convex supporting structure so as to conform to the convex curvature on the supporting structure.
6. The bracket of claim 4, wherein the perimeter contour of the supporting structure comprises an angular corner, and the rear face contour of the bracket has a V-shaped notch cut to substantially the same angle as the angular corner to conform to the angular corner on the supporting structure.
7. The bracket of claim 4, wherein the bracket comprises a hole for receiving a bracket fastener to connect the bracket to the support structure, and a cover inserted in said hole, said cover having at least one side wall and a non-planar end wall, said side wall having a sidewall length and a longitudinal slot extending though the side wall, said side wall extending into the hole with the length of said side wall completely inserted within the hole and said non-planar end wall positioned flush with the exterior contour of the bracket with no portion of the end wall protruding out of said hole, so as to visually blend the connection between the bracket and the support structure.
8. The bracket of claim 7, wherein the bracket has a curved exterior contour surrounding the hole, and the non-planar end wall of the cover has a curvature that conforms to the curved exterior contour surrounding the hole.
9. A bracket for coupling a railing member to a supporting structure, said supporting structure having a non-planar perimeter contour, said bracket comprising a socket end adapted to receive an end of the railing member and a mounting end for connection to the perimeter contour of the supporting structure, said mounting end comprising a non-planar rear surface that conforms to and mounts flush against the perimeter contour of the supporting structure to visually blend the connection between the bracket and the support structure.
10. The bracket of claim 9 comprising a railing inserted through the socket end, said railing having an outer wall that engages the socket end in a friction fit.
11. The bracket of claim 10 comprising a plurality of resilient flexible spring sheets in the socket end in frictional engagement with the outer wall of the railing, each spring sheet having a fixed end connected substantially adjacent to the socket end and a cantilevered portion extending from the fixed end toward the mounting end of the bracket.
12. The bracket of claim 9, wherein the perimeter contour of the supporting structure has a convex curvature and the rear face contour of the bracket has a concave curvature substantially identical to the curvature of the supporting structure so as to conform to the convex curvature on the supporting structure.
13. The bracket of claim 9, wherein the perimeter contour of the supporting structure comprises an angular corner, and the rear face contour of the bracket has a V-shaped notch cut to substantially the same angle as the angular corner to conform to the angular corner on the supporting structure.
14. A bracket for coupling a railing member to a post structure, said bracket forming a socket adapted to receive an end of the railing member, said bracket comprising at least one hole for receiving a bracket fastener to connect the bracket to the supporting structure, said bracket further comprising a cover inserted in said hole over said bracket fastener, said cover having at least one side wall and a non-planar end wall, said side wall having a sidewall length and a longitudinal slot extending through the side wall, said side wall extending into the hole with the length of said side wall completely inserted within the hole, and said non-planar end wall positioned flush with the exterior contour of the bracket to visually blend the connection between the bracket and the support structure.
15. The bracket of claim 14 comprising a railing inserted into the socket, said railing having an outer wall that engages the bracket in a friction fit.
16. The bracket of claim 15 comprising a plurality of resilient flexible spring sheets in the socket in frictional engagement with the outer wall of the railing, each spring sheet having a fixed end connected substantially adjacent to the socket and a cantilevered portion extending from the fixed end.
17. The bracket of claim 14, wherein said hole comprises an interior wall and a tongue projection extending along the interior wall, said longitudinal slot configured to mate with said tongue projection when the cover is inserted in the hole to substantially prevent rotational displacement of the cover relative to the interior wall of the hole.
18. The bracket of claim 14 comprising a rear face contour, wherein the rear face contour and the perimeter contour on the supporting structure have substantially identical non-planar geometries.
19. The bracket of claim 18, wherein the perimeter contour of the supporting structure has a convex curvature and the rear face contour of the bracket has a concave curvature substantially identical to the curvature of the convex supporting structure so as to conform to the convex curvature on the supporting structure.
20. The bracket of claim 18, wherein the perimeter contour of the supporting structure comprises an angular corner, and the rear face contour of the bracket has a V-shaped notch cut to substantially the same angle as the angular corner to conform to the angular corner on the supporting structure.
Type: Application
Filed: May 5, 2006
Publication Date: Sep 14, 2006
Inventors: Christopher Terrels (Ocean City, NJ), Andrew Terrels (Marmora, NJ)
Application Number: 11/418,618
International Classification: E04H 17/16 (20060101);