ADJUSTABLE MOUNTING BRACKET FOR A STAIR RAIL ASSEMBLY

Abstract

A bracket for mounting a rail to a vertical post. The bracket includes a base with an arcuate front wall and a housing that is selectively movable along that front wall. The housing itself has an arcuate front wall that is oriented at right angles to the arcuate front wall of the base. The bracket further includes a rail connector that is selectively movable along the front wall of the housing. The rail connector engages an end of the rail and holds the rail at both a vertical and a horizontal angle relative the post. The vertical and horizontal angle of the rail to the post can be changed by selectively moving the rail connector along the front wall of the housing and moving the housing along the front wall of the base.

Description

BACKGROUND OF THE INVENTION

1. Technical Field

This invention generally relates to fencing systems. More particularly, the invention relates to a rail mounting bracket. Specifically, the invention relates to a bracket that secures a rail to a vertical post and is adjustable to hold the rail and a range of vertical and horizontal angles relative to the post.

2. Background Information

The construction of a stair rail assembly requires that a hand and foot rail be secured between the vertical posts on either end of the staircase at an angle. When the stair rail assembly is being assembled from vinyl rails and posts, the installation requires more than simply butting the rail up to the post and driving a fastener into the same.

There have been several rail mounting brackets disclosed in the art for accomplishing this installation. These include devices disclosed in U.S. Pat. Nos. 6,698,726; 6,986,505; 7,044,451 and 7,147,212 to the present inventor. U.S. Pat. No. 4,767,232 issued to Francis and U.S. Pat. No. 5,026,028 issued to Ooi et al have also disclosed brackets that permit an angular mounting of a rail to a post. These previously known brackets are suitable for installations where the staircase and the rails on either side thereof are substantially parallel to each other. In these instances, the rail needs to be able to be set at a particular angle relative to the vertical and the above-referenced patents disclose brackets that enable this vertical angle to be selected. The installation is more complex when the staircase is wider at one end than at the other end. In these instances, the rails then have to angle downwardly from the top of the staircase to the bottom thereof and, at the same time, also have to diverge away from each other. Mounting these rails at the proper vertical and horizontal angle relative to the posts and to each other is more difficult.

There is therefore a need in the art for an improved rail mounting bracket for use in diverging staircases that allows for the installation of a rail at both a vertical and horizontal angle relative to the post.

SUMMARY OF THE INVENTION

The device of the present invention is a bracket for mounting a rail to a vertical post. The bracket includes a base with an arcuate front wall and a housing that is selectively movable along that front wall. The housing itself has an arcuate front wall that is oriented at right angles to the arcuate front wall of the base. The bracket further includes a rail connector that is selectively movable along the front wall of the housing. The rail connector engages an end of the rail and holds the rail at both a vertical and a horizontal angle relative the post. The vertical and horizontal angle of the rail to the post can be changed by selectively moving the rail connector along the front wall of the housing and moving the housing along the front wall of the base.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.

FIG. 1 is a front elevational view of a staircase incorporating the adjustable rail mounting brackets in accordance with the present invention;

FIG. 2 is a perspective view of the adjustable rail mounting bracket connecting a rail to a vertical post with the bracket shown in a position where the rail extends outwardly away from the vertical post and with the rail being disposed substantially horizontally and in coplanar alignment with the longitudinal axis of the post;

FIG. 3 is a perspective view of the rail mounting bracket securing the rail to the post and showing the rail positioned at an angle to the horizontal and at an angle to the longitudinal axis of the post;

FIG. 4 is an exploded perspective view showing the component parts of the rail mounting bracket;

FIG. 5 is a side view of the rail connector shown in FIG. 4;

FIG. 6 is a top view of the rail connector of FIG. 4;

FIG. 7 is a top view of the housing of FIG. 4;

FIG. 8 is a side view of the housing taken through line 8-8 of FIG. 7;

FIG. 9 is a side view of the base of FIG. 4;

FIG. 10 is a is a bottom view of the base of FIG. 4 and taken through line 10-10 of FIG. 9;

FIG. 11 is a top view of the bracket mounting the rail to the post and showing the possible range of horizontal adjustment the bracket provides;

FIG. 12 is a side view of the bracket mounting the rail to the post and showing the possible range of vertical adjustment the bracket provides;

FIG. 13 is a cross-sectional side view of the bracket mounting the rail to the post taken through line 13-13 of FIG. 2;

FIG. 13A is an enlargement of the highlighted area taken from FIG. 13;

FIG. 14 is a cross-sectional top view of the bracket mounting the rail to the post taken through line 14-14 of FIG. 13; and

FIG. 14A is an enlargement of the highlighted area taken from FIG. 14.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-14A there is shown a staircase 20 including a plurality of stairs 22, upper and lower vertical posts 24, 26, upper and lower rails 28, 30 and a plurality of spindles 32. Each rail 28, 30 is secured to one of posts 24, 26 by a rail mounting bracket 34 in accordance with the present invention. Staircase 20 is narrower at the top end 20a between upper posts 24 than at the bottom end 26b between lower posts 26. Each rail 28, 30 angles vertically downwardly from top end 20a of staircase to bottom end 20a thereof. Furthermore, 28a, 30a diverge outwardly away from rails 28b, 30b from top end 20a of staircase to the bottom end 20b thereof.

FIGS. 1 & 4 are provided with a directional reference showing a vertical axis Y and a horizontal axis X disposed at right angles to each other. For the purposes of this description, the Y-axis can be considered to aligned along a centerline that extends between the top and bottom of the side wall of post 24 as shown in FIG. 4. The X-axis is disposed at right angles thereto. Brackets 34 are provided to secure rails 28, 30 to posts 24, 26 and to allow an installer to adjust the angle the rail relative to the X and Y axes.

It will be understood brackets 34 all mount an end of one of rails 28, 30 to one of posts 24, 26 in a substantially identical manner. By way of example, FIGS. 2&3 show hand rail 28 secured to post 24 by bracket 34. Bracket 34 comprises three component parts namely a base 36, a housing 38 and a rail connector 40. Base 36 is secured to the side wall of post 24. Housing 38 engages base 36 and rail connector 40 engages housing 38. An end of rail 28 is received in rail connector 40 so that rail 28 is effectively connected to post 24 and extends outwardly away therefrom.

In accordance with the present invention, the position of housing 38 relative to base 36 may be adjusted. Furthermore, the position of rail connector 40 relative to housing 38 may be adjusted. These adjustments allow the installer to angle the rail 28 upwardly or downwardly and from one side of post 24 to the other as will be hereinafter described.

Referring to FIGS. 4-10, base 36 has an arcuate front wall 42 and a pair of opposed side walls 44, 46. Front and side walls 42, 44, 46 may be integrally formed or may be connected to each other in a suitable manner. Front wall 42 is convex and substantially semicircular in shape when viewed from the side. Front wall 42 has interior edges 48 that abut post 24 when base 36 is mounted thereon. Base 36 has a longitudinal axis “R” (FIG. 9) that extends from one interior edge 48 to the other interior edge. When base 36 is mounted on post 24, the longitudinal axis R of base 36 is substantially aligned with the vertical axis Y of post 24. Front wall 42 of base 36 describes an arc about an axis disposed at right angles to the longitudinal axis R of base. Side walls 44, 46 are planar members that are substantially semi-circular in shape. Side walls 44, 46 are recessed inwardly from an outer edge 50 of front wall 42 so that a semi-circular lip 52 is formed along the outer edge 50. A pair of spaced apart projections 54 (FIG. 10) are molded into base 36 and extend inwardly from an interior surface of front wall 42 and toward a plane aligned with interior edges 48. Projections 54 are formed with a wider first region 54a and a narrower second region 54b and define a bore that extends therethrough. The bore has an opening 56 in front wall 42 through which a fastener 58 may be introduced to secure base 36 to post 24. A shoulder 62 is formed where first region 54a of projection 54 narrows to second region 54b thereof. When a fastener 58 is introduced into the bore and is screwed into post 24, the head 60 of fastener 58 abuts shoulder 62.

Referring still to FIGS. 4-10, housing 38 comprises a front wall 64, a top wall 66, a bottom wall 68 and side walls 70, 72. Front wall 64 is arcuate in shape and joins side walls 70, 72 at side edges 74, 76 (FIG. 7). As illustrated in these figures, front wall 64 describes an arc about the Y-axis. Front, top, bottom and side walls 64-72 surround and define a cavity 78 into which at least a portion of front wall 42 of base 36 is received. A groove 80 is formed at the junction of front wall 64 with side wall 70 and at the junction of front wall 64 and side wall 72. As shown in FIG. 8, grooves 80 are substantially semicircular in shape. The grooves 80 describe and arc about the X-axis and have substantially the same radius of curvature as front wall 42 of base. Grooves 80 are therefore complementary and configured to tightly receive lip 52 of base 36 therein and thereby secure base 36 and housing 38 together. The engagement of a lip 52 in one of grooves 80 is shown in FIG. 14A.

In accordance with another feature of the present invention, a dovetail socket 82 is defined in front wall 64 of housing 38. Socket 82 is substantially aligned parallel to the X-axis and extends from side wall 70 through to side wall 72. Preferably, socket 82 is formed in front wall 64 about midway between top wall 66 and bottom wall 68.

Referring still to FIGS. 4-10, rail connector 40 includes a rear wall 84, a top wall 86, a bottom wall 88, and side walls 90, 92. Rear wall 84 is arcuate in shape, describing an arc about the Y-axis. As shown in FIG. 6, rear wall 84 is concave and has substantially the same radius of curvature as front wall 64 of housing 38. In accordance with another feature of the present invention, a dovetail tail 98 is molded into the interior surface of rear wall 84 and approximately midway between top wall 86 and bottom wall 88. Tail 98 extends rearwardly from rear wall 84 and is complementary to socket 82. When rail connector 40 is engaged with housing 38, the interior surface of rear wall 84 abuts front wall 64 and tail 98 is tightly received in socket 82.

Top, bottom and side walls 86-92 of rail connector 40 extend forwardly from an exterior surface of rear wall 84 and surround and define a receptacle 94. Receptacle 94 is complementary in shape and size to receive the end of rail 28 therein. A plurality of detents 96 are provided on one or more of interior surfaces of top, bottom and side walls 86-92 or on exterior surface of rear wall 84. Detents 96 extend into receptacle 94 and act as spacers to aid in limiting the degree to which the end of rail 28 is received in receptacle 94.

Bracket 34 is assembled and used in the following manner. Pilot holes 106 are drilled into side wall of post 24. Housing 38 and base 36 are interlockingly engaged by positioning front wall 42 of base 36 in cavity 78 of housing 38 and sliding lips 52 of front wall 42 into grooves 80. Alternatively, front wall 42 of base 36 can be positioned within cavity 78 and housing 38 can be pushed inwardly toward base 36. This movement will cause side walls 70, 72 to flex slightly outwardly, allowing lips 52 to slide along an interior surface of side walls 70, 72 and into grooves 80. Once lips 52 are engaged in grooves 80, base 36 and housing 38 are interlocked with each other and housing 38 may be slidingly moved along the arcuate front wall 42 of base 36.

Base 36 is then secured to the side wall of post 24. In order to accomplish this, housing 38 is moved in a first direction along front wall 42 to allow the installer to gain access to one of the openings 56 therein. Interior edges 48 of base 36 are brought into abutting contact with post 24 and the bores in the projection 54 is aligned with holes 106. A fastener 58 is introduced into the exposed opening 56 on front wall 42 and is threaded into hole 106 and thereby into interlocking engagement with the side wall of the post 24. Housing 38 is sliding moved along front wall 42 of base 36 in a second direction until the other of the openings 56 in front wall 42 is exposed. A second fastener 106 is introduced into this second opening 56 and is threaded into engagement with the side wall of the post 24.

Once base 36 is fixedly secured to post 24, rail connector 40 is engaged with housing 38. This is accomplished by positioning connector 40 so that one of side walls 90, 92 thereof is adjacent one of side walls 72, 74 of housing 38. Connector 40 is moved toward the other of the side walls 72, 74 so that tail 98 slides into socket 82 and rear wall 84 of connector 40 abuts front wall 64 of housing. Preferably, socket 82 is shaped so that the end regions thereof defined in the side walls 70, 72 are slightly narrowed. This makes it harder to engage tail 98 in socket 82, but also substantially prevents tail 98 from being easily pushed out of socket 82. Alternatively, socket 82 can be formed to terminate a distance inwardly from one of side walls 70, 72 so that tail 98 can be introduced into and removed from socket 82 in only one direction. When tail 98 is retained in socket 82, rail connector 40 may be slidingly moved along the arcuate front wall 64 of housing 38.

Once base 36, housing 38 and rail connector 40 are engaged with each other, the installer will adjust the various components of bracket 34 so that when the end of rail 28 is engaged in bracket 34, the rail will extend outwardly from post 24 in a desired orientation. In order to set bracket 34 so that it will hold rail 28 in the desired manner, the installer moves housing 38 along front wall 42 of base 36 so as to position the housing 38 at a desired angle relative to the X-axis. The installer adjusts the position of the rail connector 40 along the front wall 64 of housing 38 so as to position the rail connector 40 at a desired angle relative to the Y-axis. Once rail connector 40 and housing 38 are positioned at the desired orientations relative to each other and to the X and Y axes, the installer may insert a fastener 110 through the indentation 108 in rear wall 84 of rail connector 40, through front wall 64 of housing 38 and into front wall 42 to base 36 to lock the three components in their relative positions.

For example, in FIG. 12, the installer has slidingly moved housing 38 along the arcuate front wall 42 of base 36 so that housing 38 is disposed at an angle α relative to the X-axis. The angle α determines the angle at which rail 28 will ultimately extend downwardly away from post 28. So, for example if angle α is 45 degrees to the X-axis, then rail 28 will extend downwardly and outwardly from post 24 at an angle of 45 degrees. FIG. 12 also illustrates, in phantom, that housing 38 may be slid upwardly along arcuate outer wall 42 through an angle α′ relative to the X-axis. If the angle α′ is 45 degrees above the X-axis, then rail 28 will extending upwardly and outwardly away from post 24 at an angle of 45 degrees. It will be understood that since front wall 42 is substantially semicircular and housing 38 is larger than base 36, the housing 38 will likely only be able to be moved through an angle α of less than 90 degrees from the horizontal before the top or bottom walls 66, 68 thereof strike the side wall of post 24. It will be understood, however, that the relative sizes of the housing 38, base 36 and the size of angle α that housing 38 can be moved through are a matter of design choice.

FIG. 11 illustrates rail connector 40 positioned on housing 38 at an angle β to the Y-axis through point A. If the angle β is 30 degrees relative to the Y-axis, then the rail 28 will extend outwardly to the left hand side of post 24 at an angle of 30 degrees. FIG. 11 shows in phantom that rail connector can be positioned along front wall 64 of housing and an angle β′ relative to the Y-axis passing through point A. In this instance, the rail 28 will extend outwardly toward the right hand side of post 24. It will be understood that the angle β is constrained by the curvature of front wall 64 of housing 38 and the relative sizes of the housing 38 and base 36. Rail connector 40 should be adjustable through an angle β of around 180 degrees. It will be understood, that the relative sizes of the housing 38, base 36 and the size of angle β are a matter of design choice.

If the relative positions of rail connector 40, housing 38 and bracket 36 are a combination of those shown in FIG. 11 and 12, then rail 28 will extend downwardly and to the left hand side of post 24 and will be oriented at an angle of 45 degrees to the X-axis and 30 degrees to the Y-axis.

FIG. 14 shows an end of rail 28 inserted into receptacle 94 in connector 40. When the edge 28a of rail 28 abuts detents 96, rail 28 is at its maximum point of insertion into receptacle 94. Fasteners 102 are inserted through holes 100 in side walls 90, 92 of rail connector 40 and are screwed into engagement with the side walls of rail 28.

It will be understood that bracket 34 may be mounted on post 24 in such a way that front wall 42 of base 36 describes an arc about the Y-axis and front wall 64 of housing 38 describes an arc about the X-axis. However, this orientation of bracket 34 is less suitable because when rail 28 is inserted into rail connector 40, the weight of rail 28 will tend to cause rail connector 40 to want to slide out of engagement with housing 38. This will place any fastener used to secure base 36, housing 38 and rail connector 40 together under stress and may lead to failure of the bracket 34.

It will be understood that the arcuate front walls of the base and housing are disposed at right angles to each other so that a first of the front walls permits adjustment in a vertical plane and the second front wall permits adjustment in a horizontal plane. It should be understood that the vertical and horizontal adjustment can be provided by either one of the base and housing front walls. Furthermore, while the bracket of the present invention has been disclosed to have a base and a housing that each have a convex front wall and that the rail connector has a concave rear wall, it should be understood that the base, housing and rail connector may be differently formed. For example, the base may be provided with a concave front wall and then the groove in the housing is formed with a concave orientation to be engageable therewith. Furthermore, the housing may be provided with a concave front wall that engages a convex rear wall of the rail connector. In all instances, the base, housing and rail connector are formed with complementary arcuate surfaces that allow the three components to fittingly engage each other and which are individually selectively adjusted to vary one or both of the horizontal and vertical orientation of the rail.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.

Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.

Claims

1. A bracket for mounting a rail to a vertical post, wherein said bracket comprises:

a base adapted to abut a side wall of the post; said base having a first axis extending between a first and second end thereof, and wherein a front wall of said base describes an arc about a second axis that is oriented at right angles to the first axis;

a housing engageable with the base and being adjustably movable along the front wall thereof; and wherein said housing includes a front wall that describes an arc about an axis substantially parallel to the first axis of the base; and

a rail connector engageable with the housing and being adjustably movable along the front wall of the housing; and wherein said rail connector is adapted to engage an end of the rail; and wherein movement of the housing along the front wall of the base changes the orientation of the rail in one of a vertical and a horizontal plane and movement of the rail connector along the front wall of the housing changes the orientation of the rail in the other of the vertical and horizontal plane.

2. The bracket as defined in claim 1, wherein the front wall of the base is substantially semicircular and convex in shape.

3. The bracket as defined in claim 2, wherein the front wall of the housing is convex in shape.

4. The bracket as defined in claim 2, wherein the base further includes a pair of opposed side walls, each side wall extending between the first and second ends and joining the front wall of the base along an outer edge.

5. The bracket as defined in claim 4, wherein the front wall of the base further includes a lip formed along each of the outer edges, and wherein each lip extends for a distance outwardly beyond one of the side walls.

6. The bracket as defined in claim 5, wherein the base further includes at least one projection that extends inwardly from an interior surface of the front wall and substantially parallel to the side walls, and wherein said projection defines a bore adapted to receive a fastener therethrough and said bore has an opening in the front wall of the base.

7. The bracket as defined in claim 6, wherein the housing further includes at least two side walls extending rearwardly away from the front wall of the housing; and wherein each of the side wall of the housing defines an arcuate groove therein; each groove being complementary to one of the lips on the base; and wherein said lips are engageable in the grooves to secure the base and housing together.

8. The bracket as defined in claim 7, wherein the housing is adjustably movable on the front wall of the base by sliding the housing along the lips of the base.

9. The bracket as defined in claim 8, wherein the front wall of the housing includes one of a dovetail socket and a tail that is oriented substantially at right angles to the first axis of the.

10. The bracket as defined in claim 9, wherein the rail connector includes an arcuate rear wall that is complementary in shape to the front wall of the housing.

11. The bracket as defined in claim 10, wherein the rear wall defines the other of the dovetail socket and tail; and wherein the tail is receivable in the socket to retain the housing and rail connector together.

12. The bracket as defined in claim 11, wherein the rail connector further includes a peripheral wall extending forwardly and outwardly away from the rear wall thereof; and wherein said peripheral wall is adapted to engage the end of the rail.

13. The bracket as defined in claim 12, wherein the peripheral wall defines a receptacle which is adapted to receive the end of the rail therein.

14. The bracket as defined in claim 13, wherein the rail connector further includes one detent extending from one of the peripheral wall and rear wall and into the receptacle, said detent being adapted to contact the end of the rail and limit its travel into the receptacle.

15. The bracket as defined in claim 1, further comprising a fastener for securing the rail connector, housing and base together.

16. A staircase assembly comprising:

a pair of upper posts mounted vertically at the top end of a diverging staircase;

a pair of lower posts mounted vertically at the bottom end of the staircase, wherein the upper vertical posts are positioned horizontally closer to each other than are the lower posts;

at least two rails, each rail extending between one of the upper posts and one of the lower posts;

a plurality of brackets, each bracket engaging an end of one of the rails and being mounted to a side wall of one of the upper and lower posts, whereby the rail extends outwardly from the bracket and away from the post at an angle; and wherein said bracket is adjustable to change the angle at which the rail extends from the post in both a vertical and a horizontal direction.

17. The staircase assembly as defined in claim 16, wherein each bracket comprises:

a base that is secured to the post, said base having a front wall that defines an arc about one of a vertical and a horizontal axis;

a housing that is selectively movable along the front wall of the base between a first and second position; said housing having a front wall that defines a second arc about the other of the vertical and horizontal axes; and

a rail connector having a rear wall that is selectively movable along the front wall of the housing between a third and fourth position; and wherein the rail connector defines a receptacle that extends forwardly and outwardly away from the rear wall thereof; said receptacle receiving the end of one of the rails therein, whereby the rail extends outwardly away from the rear wall of the rail connector

18. The staircase assembly as defined in claim 17, wherein the base is secured to the post so that a longitudinal axis of the base is substantially parallel to a longitudinal axis of the post; and the front wall of the base defines a convex arc about an axis disposed at right angles to the longitudinal axis of the base.

19. The staircase assembly as defined in claim 18, wherein the front wall of the housing describes a convex arc about an axis disposed substantially parallel to the longitudinal axis of the base.

20. A method of connecting a rail to a vertical post at one end of a diverging staircase, said method comprising the steps of:

mounting a base onto the vertical post;

slidably engaging a housing onto an arcuate front wall of the base;

slidably engaging a rail connector onto an arcuate front wall of the housing;

sliding the housing in one of a first and a second direction along the front wall of the base and about an axis disposed substantially at right angles to a longitudinal axis of the base;

sliding the rail connector in one of a third and a fourth direction along the front wall of the housing and about an axis that is substantially parallel to the longitudinal axis of the base; and

engaging an end of the rail in a receptacle on the rail connector.