WOOD RAILING CONNECTORS

Abstract

A railing connector for mounting a railing to a post, the railing connector comprising a sleeve for receiving an end of the railing, and a flange extending from the sleeve for attachment to the post.

Description

REFERENCE TO PENDING PRIOR PATENT APPLICATION

This patent application claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 61/561,322, filed Nov. 18, 2011 by John Belli for WOOD RAILING CONNECTORS (Attorney's Docket No. JAB-25A PROV), which patent application is hereby incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to connectors in general, and more particularly to wood railing connectors for attaching a wood baluster railing to a post.

BACKGROUND OF THE INVENTION

Consider the typical railing installations shown in FIGS. 1 and 2. As seen in FIGS. 1 and 2, the rails have been toe-nailed to the post. This toe-nailing (or toe-screwing) is the currently-accepted practice for connecting rails to posts. However, this approach has many inherent problems. With gaps and twisting, this method of attachment is not only difficult to accomplish, but it is unattractive and, most importantly, unsafe.

The following is a list of some of the reasons why to-nailing (or toe-screwing) a rail to a post is so undesirable.

1. Gaps can develop between the rail and post. Over time, the rails and post will shrink and tend to pull away from each other. These gaps will increase with time and weaken the railing.

2. Toe-nailing (and toe-screwing) tends to split the rail end during installation and this split tends to get worse with time. If the nail (or screw) is not driven at the correct angle, it can crack the rail end during installation and make the entire rail useless.

3. With toe-nailing (or toe-screwing), there is no way to tell how much of the nail (or screw) went into the post. The depth is determined by the angle of the nail-gun (or screw-inserter) when it is driven. This means that even though a long heavy gauge screw may have been used, there may be very little attachment to the post.

4. Toe-nailing (or toe-screwing) usually does not secure the rail end sufficiently to avoid a twist in the rail. All pressure-treated lumber tends to twist as it dries over time. This can cause detachment from the post and detachment of balusters.

5. Toe-nailing (or toe-screwing) can provide a messy, unattractive appearance. Nails or screws are placed randomly and commonly not set.

Recently, the regulations for attaching a post to a deck have changed, and strength requirements for attaching a post to a deck have almost doubled. With these new post-to-deck strength regulations, it is anticipated that health and building regulators will soon require a better means for attaching the railing to the post. A new system will be required to provide the strength desired.

Thus there is a need for a new and improved approach for attaching a rail to a post.

SUMMARY OF THE INVENTION

The present invention provides a new and improved approach for attaching a rail to a post. More particularly, the present invention provides novel wood railing connectors for attaching a rail to a post.

In one preferred form of the present invention there is provided a railing connector for mounting a railing to a post, the railing connector comprising a sleeve for receiving an end of the railing, and a flange extending from the sleeve for attachment to the post.

In another preferred form of the present invention there is provided a method for mounting a railing to a post, the method comprising: providing a railing connector for mounting a railing to a post, the railing connector comprising a sleeve for receiving an end of the railing, and a flange extending from the sleeve for attachment to the post; and

positioning an end of the railing in the sleeve and securing the flange to the post.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the preferred embodiments of the invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts, and further wherein:

FIGS. 1 and 2 are schematic views showing current forms of rail attachment to a post;

FIGS. 3 and 4 are schematic views showing a common railing configuration; and

FIGS. 5-14 are schematic views showing novel wood railing connectors for attaching a rail to a post.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention provides a new and improved approach for attaching a rail to a post. More particularly, the present invention provides novel wood railing connectors for attaching a rail to a post.

The novel wood railing connectors of the present invention are designed to eliminate or reduce the problems associated with the current form of rail attachment (i.e., toe-nailing or toe-screwing). With the present invention, even the homeowner with little construction experience will find it fast and easy to construct a strong, safe, and attractive railing system for a deck, retaining wall, or similar applications. The novel wood railing connectors of the present invention are metal (or plastic) flanges made to fit the associated rail end (nominal size, usually 2×4) and attach the rail end to a post or wall. In accordance with the present invention, several different embodiments of wood railing connectors are disclosed below. Each embodiment exhibits a unique geometry to solve specific problems associated with the slight variations in the configuration of railings today. Each wood railing connector includes a flange mounting surface which is shaped to fit an intended location against a post. The flange mounting surfaces contain holes to accept nails or screws in strategic locations to rigidly secure the rail to the post. Each wood railing connector includes a sleeve which is designed to hold the rail securely and hide any gaps that may occur during the construction of the railing, in addition to any gaps that may develop later over time. In most of the embodiments disclosed below, nails or screws are driven “perpendicularly” into the wood surfaces, creating a strong attachment, much stronger than toe-nailing or toe-screwing. Quicker and easier to install, removable, more attractive, longer lasting, and most of all—safer!

The most common railing configuration is shown in FIGS. 3 and 4. As seen in FIGS. 3 and 4, a 2×4 railing cap is used at the top of the railing. This 2×4 cap is wide enough to cover both the top rail and top of the balusters. In addition, it is positioned in line to cross over the top of the 4×4 post. Because of this requirement, both top and bottom rails end up being positioned flush, or close to flush, with the face of the post. This ensures that the top rail and top of the balusters remain under the rail cap, and in line with the posts. This also dictates that all of the connectors of the present invention must be made without the flange portion of the connector on one side.

From this common rail configuration, the following flange geometries have been created. Each type of connector is designed to accommodate this railing configuration and any slight variations:

1. Closed-end, flush;

2. Open-end, flush, with or without rib;

3. Closed-end, unsecured overlap;

4. Open-end, unsecured overlap, with or without rib;

5. Closed-end, secured overlap; and

6. Open-end, secured overlap, with or without rib.

Closed/Open End.

This nomenclature refers to one end of the connector. “Closed” indicates the connector forms a continuous loop around the end of the rail. It has a flange portion and sleeve portion at each end of it. “Open” indicates that one end of the connector appears to have been cut off. In this case, the flange and sleeve portion at this end of the connector is missing. See FIG. 5. In most cases the top rail connector will be an open-end to allow the rail to fit up against the bottom of the rail cap.

Flush/Overlap.

This nomenclature indicates the connector has, or does not have, an extension member beyond it's face. It basically defines the connector as a “flat back” or not. “Flush” indicated the connector is a “flat back” and it does not have an overlap. In this case, when the connector is used, it rests on one face of the post only. The rail is typically positioned slightly back from the edge of the post by the thickness of the sleeve, at minimum. Remember that the most common configuration (shown in FIGS. 3 and 4) dictates that the rail must be positioned close to the edge of the post. FIG. 6 shows an example of a closed-end flush connector. “Overlap” indicates the connector has an extension member that wraps around the edge of the post. In this case the connector is actually resting against two faces of the post. To allow this, the rail must be in line with the edge of the post. See FIG. 7, which shows an example of an open-end secured overlap connector.

Secured/Unsecured.

This nomenclature refers to the type of overlap, if one exists. “Secured” indicates there are screw holes in the overlap. Similarly, “Unsecured” indicates there are no holes in the overlap. See FIG. 8, which is an example of an open-end, unsecured overlap connector.

With or Without Rib.

This nomenclature refers to a strengthening rib which may be desired to strengthen the open end of the open-end parts. This rib ties the ends together, making it less likely that the connector can twist. In most cases, the rib will contain a hole for a securing nail or screw. With the rib, however, the connector cannot be “slid” onto an existing railing. (See section below on “Use For Strengthening Existing Railings”). Likewise, once the railing is constructed, any disassembly is more difficult because the rib nail or rib screw lies under the end of the rail and is less accessible. See FIG. 9, which is an example of an open end, flush with rib connector.

Various Examples of the Present Invention

FIGS. 10-14 show various examples of the present invention.

Use for Strengthening Existing Railings.

Some versions of the wood rail connectors of the present invention can be used on existing railings, as well as new construction. Their geometry allows them to be slipped into place without the need of rebuilding an existing railing. These are the open-end versions.

For this purpose, the connectors must be made open-ended, and with no web. In this way, it is possible to “add” them to existing railings without rebuilding the railing, thereby increasing the strength dramatically. The top connector is slipped under the top rail into position, and the bottom connector is slipped down over the bottom rail into position. With the “perpendicular” insertion of nails or screws into the post and rails, any existing railing system would become much stronger. The existing toe-nails or toe-screws would remain in the railing, as is, under the connectors. The open end of the bottom connector would not be obvious because it is under the bottom rail and the open end of the top connector would be covered by the rail cap. In addition to strengthening the railing, these connectors would also cover any ugly gaps between the rail and post that may have developed over time.

Still another variation of a connector that could be used to strengthen an existing railing would involve the closed version, but slightly flexible with a “break” at one corner, so that the connector could be twisted apart, slid into position, and re-configured to fit the location. Still another variation would involve a “two piece” connector.

Stair Railing Connectors.

The present invention also provides a novel connector which can be used to connect railings to posts (or walls) on stairs. Traditionally during construction, the angle cut on these rail ends are most difficult to make because they must be duplicated to the precise angle for each of the rails involved. A slight variation in the angle of one cut will result in an ugly gap and a weakened attachment or a scrapped rail. In addition, with the angle cut, the large end-grain exposure tends to curl the rail end quicker over time. The novel connector of the present invention eliminates this problem. The rail ends are securely held within the sleeve of the novel connector whether they are cut accurately or not. The rail ends cannot curl as they weather over time because they are held flat and securely within the novel connector sleeve. When designing this part, a nominal angle was selected with enough clearance in the sleeve to accommodate any stair case angle. Variations of this connector can accommodate any type of installation (i.e., top/bottom rail, center/flush post attachment, with or without rail cap).

Alternative Geometries.

FIGS. 5-14 show the connectors of the present invention exhibiting a “flange” type of geometry; specifically, a base plate portion for connection to a surface, and a sleeve portion to hold the rail. It should be noted that in these areas of the connectors, both portions could be combined to form a “beveled” geometry that appears to wrap around the rail end. Perpendicular nail or screw attachment in both rail and post can still be achieved through countersunk holes. In some areas angular nail or screw attachment would still be sufficient.

MODIFICATIONS

While the present invention has been described in terms of certain exemplary preferred embodiments, it will be readily understood and appreciated by those skilled in the art that it is not so limited, and that many additions, deletions and modifications may be made to the preferred embodiments discussed herein without departing from the scope of the invention.

Claims

1. A railing connector for mounting a railing to a post, the railing connector comprising a sleeve for receiving an end of the railing, and a flange extending from the sleeve for attachment to the post.

2. A method for mounting a railing to a post, the method comprising:

providing a railing connector for mounting a railing to a post, the railing connector comprising a sleeve for receiving an end of the railing, and a flange extending from the sleeve for attachment to the post; and

positioning an end of the railing in the sleeve and securing the flange to the post.