US20230228097A1 - Raking rail panel and bracket system and method - Google Patents
Raking rail panel and bracket system and method Download PDFInfo
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- US20230228097A1 US20230228097A1 US18/186,637 US202318186637A US2023228097A1 US 20230228097 A1 US20230228097 A1 US 20230228097A1 US 202318186637 A US202318186637 A US 202318186637A US 2023228097 A1 US2023228097 A1 US 2023228097A1
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- post
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F11/00—Stairways, ramps, or like structures; Balustrades; Handrails
- E04F11/18—Balustrades; Handrails
- E04F11/181—Balustrades
- E04F11/1817—Connections therefor
- E04F11/1834—Connections therefor with adjustable angle, e.g. pivotal connections
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F11/00—Stairways, ramps, or like structures; Balustrades; Handrails
- E04F11/18—Balustrades; Handrails
- E04F11/181—Balustrades
- E04F11/1842—Balusters; Grille-type elements
- E04F11/1844—Grille-type elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F11/00—Stairways, ramps, or like structures; Balustrades; Handrails
- E04F11/18—Balustrades; Handrails
- E04F11/181—Balustrades
- E04F11/1817—Connections therefor
- E04F2011/1819—Connections therefor between balustrade posts and horizontal or sloping balustrade members
Definitions
- the present disclosure relates to construction materials, and more particularly to a rail panel and bracket system that is easily installed in a range of rake angles.
- Conventional raked or raking (sometimes referred to as racked or racking) rail panels are difficult to install and often require more than one person.
- the pivot point of the rail bracket is not aligned with the pivot point of the balusters. This frustrates angle adjustability for a pre-assembled rail panel because the angle of the brackets and the angle of the rail panel are not simultaneously adjustable.
- precise measuring and prepositioning is required to ensure that the installation properly accounts for a slope of the stairway (i.e. rake angle).
- FIG. 1 A illustrates installation of a conventional raking rail panel 10 on a stairway 12 .
- the rail panel 10 includes a top rail 14 and a bottom rail 16 separated by balusters 18 .
- the balusters 18 are collectively pivotable with respect to the top rail 14 and the bottom rail 16 . It is important for a professional looking installation that the rail panel appear to be centered within the elevated vertical support post 20 a and the descended vertical support post 20 b .
- the horizontal distance 22 from the elevated vertical support post 20 a to an adjacent baluster 18 should equal the horizontal distance 24 from the descended vertical support post 20 b to an adjacent baluster 18 .
- balusters are parallel to the vertical support posts.
- the geometry that arises when raked top and bottom rails intersect a support post complicates installation because the top and bottom rails are cut with unequal lengths of mountable extension portions as measured from an adjacent baluster.
- To accurately measure such unequal lengths it is often necessary to preposition the panel on a set of support blocks 26 and mark the top and bottom rails for cutting. Prepositioning the panel is cumbersome and may even result in damage to the rail panel and also possibly to the vertical support posts.
- FIG. 1 B shows the raking rail panel in a straight or square configuration with cutting marks that arise when the prepositioned panel is marked. Cutting marks 27 , 29 are marked closer to the end baluster 18 on the cut rail panel; cutting marks 23 , 25 are marked further away from the end baluster 18 on the cut rail panel.
- FIG. 1 C shows the cut panel 30 in a raked configuration. The panel is cut such that mountable extension lengths 36 , 38 of the top and bottom rails 14 , 16 are less than mountable extension lengths 32 , 34 of the top and bottom rails 14 , 16 . The extension lengths will be different for railing installations at different rake angles. It can be observed from FIG.
- top and bottom rails are prepositioned, measured, marked, and cut, as described above, the balusters may be installed in a vertical orientation between the top and bottom rails.
- Embodiments of the present disclosure include a raking rail panel system.
- the system includes a raking rail panel supported by four pivotable bracket assemblies.
- Each pivotable bracket assembly includes a rail support bracket that is hinged to a post bracket.
- Each post bracket is configured to be coupled to a vertical support post.
- the post brackets each include a gap filling portion that extends from a mounting face of the vertical support posts.
- the gap filling portions are sized to either fill a long or a short gap between an end baluster and the vertical support post.
- the four pivotable bracket assemblies facilitate drop-in installation of the rail panel pivoted in a range of rake angles.
- a method for installing a raking rail panel includes positioning a first pivotable bracket assembly on a face of an elevated vertical support post.
- a second pivotable bracket assembly is positioned on a descended vertical support post.
- a distance between the first and second pivotable bracket assemblies is measured, and then marked on a top rail and a bottom rail.
- the top and bottom rails are cut to have equal mounting extension lengths.
- the cut bottom rail is dropped in to the first and second pivotable bracket assemblies.
- inventions of the raking rail panel system and method according to the teachings of the present disclosure include accommodation of a range of rake angles by the pivotable bracket assemblies.
- the bracket assemblies close a gap that would otherwise result if the top and bottom rails were cut to have four equal extension lengths.
- measuring and marking is performed without requiring prepositioning of the uncut raking rail panel, so one person can easily install a raking rail panel on a staircase.
- FIG. 1 A- 1 C illustrate steps of an installation of a prior art raking rail panel
- FIG. 2 illustrates early steps in an installation of a raking rail panel and gap filling pivotable bracket assemblies according to the teachings of the present disclosure
- FIGS. 3 A- 3 B are an isometric view and an elevation view of a short post bracket
- FIGS. 4 A- 4 B are an isometric view and an elevation view of an extended post bracket
- FIG. 5 is an isometric view of a bottom rail support bracket
- FIG. 6 is an isometric view of a top rail support bracket
- FIGS. 7 A- 7 D illustrate embodiments of pivotable bracket assemblies used to support a raking rail panel according to the teachings of the present disclosure
- FIG. 8 illustrates a step in a process of installing a raking rail panel according to the teachings of the present disclosure.
- FIG. 9 illustrates a raking rail panel installed in pivotable bracket assemblies according to the teachings of the present disclosure.
- FIG. 2 illustrates a step in the installation of a raking rail panel 40 (see FIG. 9 ).
- the raking rail panel 40 is preassembled and includes a top rail 42 and a bottom rail 44 vertically spaced apart from the top rail 42 .
- Balusters 46 also known as uprights or pickets, extend between the top and bottom rails 42 , 44 .
- the balusters 46 are horizontally spaced apart and collectively form the barrier portion of the rail panel 10 .
- Each of the balusters 46 is pivotally coupled to the top and bottom rails 42 , 44 . Such pivotal coupling allows the top and bottom rails 42 , 44 to be angled to correspond to an angle of a staircase 48 , while the balusters 46 pivot to stay vertical.
- the rail panel 40 is configured for easy installation in a raked configuration according to the teachings of the present disclosure.
- the raked rail panel 40 is installed as a rail barrier for a stairway 48 .
- the raked rail panel 40 may be installed in sloping configurations common to stairways.
- the installer will cut the preassembled rail panel 40 to the precise length required for the preassembled rail panel 40 to fit and be supported by an elevated vertical support post 50 and a descended vertical support post 52 .
- the pivotable bracket assemblies according to the teachings of the present disclosure support drop-in installation of the cut preassembled rail panel 40 .
- the pivotable bracket assemblies 60 , 62 , 64 , 66 support a drop in installation of the cut raking rail panel 40 .
- This is a significant advantage for the installer as it allows the installer set the vertical post members, install the brackets, and then drop the railing, panel or other structure, for example a railing where cables form the primary barrier, into place. This also supports installation with the use of fewer personnel and with an easier and quicker installation and assembly time.
- the preassembled rail panel 40 may be any suitable length.
- the preassembled rail panel is approximately six feet in length, and in an alternate embodiment, the preassembled rail panel is approximately eight feet in length.
- an installer may measure a length of the preassembled rail panel that corresponds to a distance between faces of vertical support posts that are attached to the stairway 48 , the top and bottom rails 42 , 44 are cut to the measured length, and the cut, preassembled rail panel 40 is then dropped into pivotable bracket assemblies that have been previously attached to the vertical support posts 50 , 52 .
- a mountable extension of the top rail 42 extends the same length from an adjacent baluster 46 as a mountable extension of a bottom rail 44 .
- each support post 50 , 52 may be attached to a wooden stair that has been blocked between rim joists. Hex head bolts are received through preformed holes formed in a flange at the base of the post to secure the post to the stairway 48 .
- the posts may be of any suitable metal, for example galvanized steel or aluminum. According to an alternate embodiment, the posts may be made of wood or a durable polymer material.
- a pair of pivotable bracket assemblies is mounted to each vertical support post 50 , 52 .
- the four pivotable bracket assemblies include an elevated, bottom assembly 60 , a descended bottom assembly 62 , an elevated, top assembly 64 , and a descended, top assembly 66 .
- the pivotable bracket assemblies 60 , 62 , 64 , 66 serve multiple functions.
- the pivotable bracket assemblies support the top and bottom rails 42 , 44 .
- the pivotable bracket assemblies also close or otherwise fill a gap between ends of the top and bottom rails 42 , 44 and the mounting surface of the vertical support posts 50 , 52 .
- the pivotable bracket assemblies are pivotable to accommodate a range of rake angles ⁇ of the rail panel 40 .
- the raking rail panel 40 is pivotable to accommodate rake angles ⁇ in a range of 0-45 degrees.
- the pivotable bracket assemblies are pivotable to accommodate rake angles ⁇ in a range of 29-40 degrees measured from horizontal, which allows installation on stairways with gradual or steeper slopes.
- each pivtoable bracket assembly includes two components coupled together by a hinge. Manufacturing of the pivotable brackets 60 , 62 , 64 , 66 is simplified because the eight components are formed from four separate parts that are assembled in different configurations, as described in further detail below. Thus, the system 10 is manufactured with four separate bracket parts, with two of each provided in a kit along with instructions to install the raking rail panel.
- a long straight two-by-four piece of wood is positioned on the stairway such that its wide face contacts the upper most edge of each stair. This establishes the slope of the stairway. Marks are made on interior faces of the vertical support posts 50 , 52 to mark the location of the lower pivotable bracket assemblies 60 , 62 . The two-by-four also mimics the location of the position of the installed bottom rail 44 .
- FIGS. 3 A and 3 B are an isometric view and a side, elevation view of the gap filling post bracket 70 .
- the gap filling post bracket 70 may be referred to a short post bracket because it is shorter to fill a shorter gap distance between the face of the elevated vertical support post 50 and the end of the bottom rail 44 , unlike a extended gap filling post bracket 100 , which fills a larger gap distance between the end of the top rail 42 and the face of the elevated vertical support post 50 .
- the short post bracket 70 includes a generally flat rear mounting surface 72 that contacts the mounting face of the vertical support post 50 , 52 .
- a center through hole 74 receives a fastener to secure the short post bracket 70 to the vertical support post 50 , 52 .
- the center through hole 74 is countersunk to ensure that the head of the mounting screw is flush. The flush head of the mounting screw does not interfere with the arm of the rail support bracket.
- a second fastener is received through an outer slot 76 .
- the slot 76 allows adjustment of an angle of the short post bracket 70 to ensure it is vertical and aligned with the vertical support post 50 , 52 , in the event the holes were not drilled in the vertical support post in vertical alignment.
- the slot 76 is formed through an arcuate flange 78 or tab.
- a body of the short pivotable bracket 70 defines a pivot arm receiving cavity 80 .
- the arm receiving cavity 80 is defined by a floor surface 82 and a pair of sidewalls 84 disposed on opposite sides of the floor surface 82 .
- the arm receiving cavity 80 receives an arm portion of a rail support bracket (shown and described below with respect to FIGS. 5 and 6 ) and allows the rail support bracket to pivot in one angular direction, but pivoting in the opposite angular direction is constrained by the floor surface 82 .
- a hinge hole 86 extends through the body.
- the hinge hole 86 receives a barrel 88 at one end and a screw 90 is received in the other end of the hinge hole 86 and threadedly engages the barrel 88 (see FIGS. 7 A and 7 D ).
- the barrel 88 is a bearing surface that supports pivoting of the rail support bracket with respect to the fixed short gap filling post bracket 70 .
- the body also includes an arcuate surface 92 that corresponds to an arcuate surface of the rail support bracket, as described with respect to FIGS. 5 and 6 .
- a length 94 that the body extends from the rear mounting face 72 may be in a range of 1-2 inches, for example approximately 1.77 inches.
- a height of the mounting face 72 may be in a range of 1-4 inches, for example approximately 2.68 inches. These dimensions ensure that the short gap filling post bracket 70 fills the short gap between a face of the vertical support post 50 , 52 and the ends of the top and bottom rails 42 , 44 .
- the short gap filling post bracket 70 is formed by die casting metal, such as aluminum or steel, and machining the die cast aluminum or steel. According to one embodiment, the short gap filling post bracket 70 is formed by die casting an aluminum alloy, for example ADC 12 , and machining the cast structure to form the illustrated features. Alternatively, the short gap filling post bracket 70 may be formed by molding a durable polymeric material.
- FIGS. 4 A and 4 B are an isometric view and a side, elevation view of the extended gap filling post bracket 100 .
- the gap filling post bracket 100 may be referred to a long post bracket because it is longer to fill a larger gap distance between the face of the lower vertical support post 52 and the end of the bottom rail 44 , unlike the short gap filling post bracket 70 , which fills the shorter gap distance.
- the extended post bracket 100 includes a generally flat rear mounting surface 102 that contacts the mounting face of the vertical support post 50 , 52 .
- a center through hole 104 receives a fastener to secure the extended post bracket 100 to the vertical support post 50 , 52 .
- the center through hole 104 is countersunk to ensure that the head of the mounting screw is flush. The flush head of the mounting screw does not interfere with the arm of the rail support bracket.
- a second fastener is received through an outer slot 106 formed in an arcuate flange 108 or alternatively a tab. The slot 106 allows adjustment of an angle of the extended post bracket 100 to ensure it is vertical and aligned with the vertical support post 50 , 52 , in the event the holes were not drilled in the vertical support post in vertical alignment.
- a body of the extended pivotable bracket 100 defines a pivot arm receiving cavity 110 .
- the arm receiving cavity 110 is defined by a floor surface 112 and a pair of sidewalls 114 disposed on opposite sides of the floor surface 112 .
- the arm receiving cavity 110 receives the arm portion of the rail support bracket (described and shown below with respect to FIGS. 5 and 6 ) and allows the rail support bracket to pivot in one angular direction, but pivoting in the opposite angular direction is constrained by the floor surface 112 .
- a hinge hole 116 extends through the body.
- the hinge hole 116 receives a barrel 88 at one end and a screw 90 is received in the other end of the hinge hole 116 and threadedly engages the barrel 88 (see FIGS. 7 B and 7 C ).
- the barrel 88 is a bearing surface that supports pivoting of the rail support bracket with respect to the fixed extended gap filling post bracket 100 .
- the body also includes an arcuate surface 118 that corresponds to an arcuate surface of the rail support bracket, as described with respect to FIGS. 5 and 6 .
- the arcuate surface 118 transitions to a slanted surface 120 that is delimited by the rear mounting surface 102 .
- the slanted surface 120 is generally aligned with a top surface of either the top or bottom rail 42 , 44 in multiple rake angles when the raking rail panel is held by the pivtoable bracket assemblies.
- a length 122 that the body extends from the rear mounting face 102 may be in a range of 2-3 inches, for example approximately 2.28 inches.
- a height of the mounting face may be in a range of 2-5 inches, for example approximately 3.41 inches. These dimensions ensure that the extended gap filling post bracket 100 fills the larger gap between a face of the vertical support post 50 , 52 and the ends of the top and bottom rails 42 , 44 .
- the extended gap filling post bracket 100 is formed by die casting metal, such as aluminum or steel, and machining the die cast aluminum or steel. According to one embodiment, the extended gap filling post bracket 100 is formed by die casting an aluminum alloy, for example ADC 12 , and machining the cast structure to form the illustrated features. Alternatively, extended gap filling post bracket 100 may be formed by molding a durable polymeric material.
- drill locations corresponding to the center through hole 104 and outer slot 106 of the extended post bracket 100 are marked on the elevated vertical support post 50 a predetermined distance above the drill locations of the short post bracket 70 .
- the extended post bracket is inverted such that the slot 106 is disposed closest to the lower/short post bracket 70 .
- the mark for the center through hole 104 corresponds to a height of the preassembled raking rail panel 40 .
- the height of the preassembled rail panel 40 is approximately 29.5 inches.
- the preassembled raking rail panel 40 has a height of 35.5 inches. This disclosure contemplates any suitable height rail panel 40 .
- the marking for the locations of the upper pivotable post brackets 64 , 66 can be made using known distances based on the known height of the raking rail panel.
- a template with holes marked at the proper locations may be provided with the raking rail panel 40 and the pivotable bracket assemblies 60 , 62 , 64 , 66 .
- the distances may be measured by the installer but prepositioning the uncut rail panel is not required.
- top and bottom rail brackets facilitated by the pivotable bracket assemblies represents an improvement over conventional brackets because with conventional raking rail panel installations using conventional brackets, the positioning of a top bracket with respect to a bottom bracket varies, at least slightly, depending on the rake angle.
- FIG. 5 is an isometric view of a rail support bracket 130 configured to support the lower rail 44 of the preassembled rail panel 40 .
- the lower rail support bracket 130 includes a rail support cup 132 sized to receive an end of the bottom rail 44 .
- a pivot arm 134 extends from a rear of the cup 132 .
- a portion supporting an arcuate surface 135 also extends from the rear of the cup 132 .
- the bottom rail support bracket 130 is formed by die casting metal, such as aluminum or steel, and machining the die cast aluminum or steel. According to one embodiment, the bottom rail support bracket 130 is formed by die casting an aluminum alloy, for example ADC 12 , and machining the cast structure to form the illustrated features. Alternatively, the bottom rail support bracket 130 may be formed by molding a durable polymeric material.
- the bottom rail support bracket 130 includes four adjacent sides of a cube-like structure with openings in the top and the front of the cube-like structure to allow an end of the bottom rail 44 to be dropped into the cup 132 .
- the four adjacent sides of the cup 132 comprise a bottom wall or floor 136 , a pair of opposed side walls 138 , and a rear/back wall 140 .
- the pair of opposed side walls 138 and back wall 140 extend perpendicularly from the bottom wall 136 .
- the bottom wall 136 provides a primary support for receiving the end of the bottom rail 44 .
- the weight of the bottom rail 44 and any downward force on the bottom rail 44 is opposed, at least in part, by the bottom wall 136 .
- the side walls 138 provide for lateral retention of the received end of the bottom rail 44 .
- At least one of the side walls 138 and in the illustrated embodiment both side walls 138 , includes at least one countersunk hole 142 , for example two countersunk holes 142 .
- the holes 142 support insertion of a mounting screw through the hole 142 for attachment to a side of the bottom rail 44 . This attachment may be made into and through the side of the bottom rail 44 member (using an opening therein) or alternatively against the side surface of the bottom rail 44 (such as with the use of a set screw or self-tapping screw).
- the side walls 138 further function to restrain longitudinal movement of the received bottom rail 44 (i.e., removal of the end of the bottom rail from the cup 132 ).
- the bottom rail 44 may be sufficiently secured within the cup 132 with a fastener received through only one countersunk hole per side wall 138 .
- the pivot arm 134 extends from the cup at a non-perpendicular angle. At a distal end of the arm 134 , a through hole 144 is formed. The through hole 144 receives the barrel 88 of the hinge assembly when the rail support bracket 130 is coupled to the short or extended post bracket 70 , 100 .
- the pivot arm 134 includes a top surface 146 and a bottom surface 148 . When the bottom surface 148 contacts the floor surface 82 , 112 defining the cavity 80 , 110 of the post bracket 70 , 100 the top surface 146 is generally flush with the post bracket 70 , 100 .
- the pivot arm 134 is configured to pivot away from contact with the floor surface 82 , 112 and away from flush with the post bracket 70 , 100 to accommodate different angles of the slope of the top and bottom rails 42 , 44 , which corresponds to the slope of the stairway 48 .
- the pivotable brackets 60 , 62 , 64 , 66 and preassembled raking rail panel 40 adjusts to accommodate an angle between 29-40 degrees from horizontal.
- the portion that includes the arcuate surface 135 is disposed below the pivot arm 134 and proximate the floor 136 of the cup 132 .
- the arcuate surface 135 corresponds to the arcuate surfaces 92 , 118 of both the short and the extended post brackets 70 , 100 .
- FIG. 6 illustrates a rail support bracket 150 configured to support an upper or top rail 42 of the preassembled rail panel 40 .
- the top rail support bracket 150 includes a rail support cup 152 sized to receive an end of the top rail 42 .
- a pivot arm 154 extends from a rear of the cup 152 .
- a portion supporting an arcuate surface 155 also extends from the rear of the cup 152 .
- the top rail support bracket 150 is formed by die casting metal, such as aluminum or steel, and machining the die cast aluminum or steel. According to one embodiment, the top rail support bracket 150 is formed by die casting an aluminum alloy, for example ADC 12 , and machining the cast structure to form the illustrated features. Alternatively, the top rail support bracket 150 may be formed by molding a durable polymeric material.
- the top rail support bracket 150 includes four adjacent sides of a cube-like structure with openings in the top and the front of the cube-like structure with openings in the top and the front of the cube-like structure to allow an end of the top rail 42 to be dropped into the cup 152 .
- the four adjacent sides of the cup 152 comprise a bottom wall or floor 156 , a pair of opposed side walls 158 , and a rear/back wall 160 .
- the pair of opposed side walls 158 and back wall 160 extend perpendicularly from the bottom wall 156 .
- the bottom wall 156 provides a primary support for receiving the end of the top rail 42 .
- the weight of the top rail 42 and any downward force on the top rail 42 is opposed, at least in part, by the bottom wall 156 .
- the side walls 158 provide for lateral retention of the received end of the top rail 42 .
- At least one of the side walls 158 and in the illustrated embodiment both side walls 158 , includes at least one countersunk hole 162 , for example two countersunk holes 162 .
- the holes 162 support insertion of a mounting screw through the hole 162 for attachment to a side of the top rail 42 . This attachment may be made into and through the side of the top rail 42 (using an opening therein) or alternatively against the side surface of the top rail 42 (such as with the use of a set screw or self-tapping screw).
- the side walls 158 further function to restrain longitudinal movement of the received top rail 42 (i.e., removal of the end of the bottom rail from the cup 152 ).
- the top rail 42 may be sufficiently secured within the cup 152 with a fastener received through only one countersunk hole per side wall 158 .
- the pivot arm 154 extends from the cup 152 at an angle. At a distal end of the arm 154 , a through hole 164 is formed. The through hole 164 receives the barrel 88 of the hinge assembly when the rail support bracket 150 is coupled to the short or extended post bracket 70 , 100 .
- the pivot arm 154 includes a top surface 166 and a bottom surface 168 . When the bottom surface 168 contacts the floor surface 82 , 112 defining the cavity 80 , 114 of the post bracket 70 , 100 the top surface 166 is generally flush with the post bracket 70 , 100 .
- the pivot arm 154 is configured to pivot away from contact with the floor surface 82 , 112 and away from flush with the post bracket 70 , 100 to accommodate different angles of the slope of the top and bottom rails 42 , 44 , which corresponds to the slope of the stairway 48 .
- the pivotable brackets 60 , 62 , 64 , 66 and preassembled raking rail panel 40 adjusts to accommodate an angle between 29-40 degrees from horizontal.
- the top rail support bracket 150 is similar to the bottom rail support bracket 130 with the exception of the location of a lever arm 154 and the hinge hole 164 formed in the lever arm 154 with respect to a floor surface 156 of the cup 152 .
- the pivot arm 154 is located below the arcuate surface 155 proximate the floor 156 of the cup 152 .
- the bottom rail support bracket 130 is similar to the top rail support bracket 150 with the exception of the location of the respective floor surfaces 136 , 156 .
- the bottom rail support bracket 130 can be transformed into the top rail support bracket by relocating the floor surface from a bottom portion of the cube-like structure to the top portion of the cube like structure.
- the rail support brackets may be stamped or otherwise marked with an indicator, such as a letter “B,” indicating that the bracket is to be used to support the bottom rail 44 or a “T” to indicate that the bracket is to be used to support the top rail.
- an “S” may be stamped or otherwise marked in the short post bracket 70
- an “L” may be stamped or otherwise marked in the extended (i.e. long) post bracket 100 .
- FIGS. 7 A- 7 D the pivotable bracket assemblies are coupled to the elevated and descended vertical support posts 50 , 52 in position to hold the top rail 42 and bottom rail 44 .
- FIG. 7 A is an isometric, exploded view of the elevated, bottom assembly 60 , which includes the short post bracket 70 hinged to the bottom rail support bracket 130 , with the post mounting slot 76 of the short post bracket 70 oriented upward.
- FIG. 7 B is an isometric, exploded view of the descended bottom assembly 62 , which includes the extended post bracket 100 hinged to the bottom rail support bracket 130 with the post mounting slot 106 of the extended post bracket 100 oriented upward.
- FIG. 7 A is an isometric, exploded view of the elevated, bottom assembly 60 , which includes the short post bracket 70 hinged to the bottom rail support bracket 130 , with the post mounting slot 106 of the extended post bracket 100 oriented upward.
- FIG. 7 A is an isometric, exploded view of the elevated, bottom assembly 60 , which includes the short post bracket 70 hinged to the bottom
- FIG. 7 C is an isometric, exploded view of the elevated, top assembly 64 , which includes the extended post bracket 100 hinged to the top rail support bracket 150 with the post mounting slot 106 of the extended post bracket 100 oriented downward.
- FIG. 7 D is an isometric, exploded view of the descended, top assembly 66 , which includes the short post bracket 70 hinged to the top rail support bracket 150 with the post mounting slot 76 of the short post bracket 70 oriented downward.
- each cup 132 , 152 are disposed facing generally upward.
- the floor surfaces 136 , 156 , the rear walls 140 , 160 , and the side walls 138 , 158 are open from the top to allow the installer to place the top and bottom rails 42 , 44 in each of the four cups.
- the pivotability of the cups 132 , 152 with respect to the vertical support posts and the post brackets 70 , 100 allows virtually automatic adjustment to accommodate multiple slope angles. The is automatically accommodated without requiring angle cuts on the end of the rail, or offset cuts with respect to the top and bottom rails 42 , 44 .
- the system presents an aesthetically pleasing appearance at least in part because the gaps associated with the geometry of a raked rail panel are closed by the pivotable brackets 60 , 62 , 64 , 66 .
- a measurement 169 is made at the rake angle ⁇ from the rear wall 140 of the elevated, bottom assembly 60 to the rear wall 140 of the descended bottom assembly 62 is taken.
- This measurement 169 can be marked on the top rail 42 and the bottom rail 44 .
- the top and bottom rails are marked to leave at least 1 and 3 ⁇ 8 inches of each of the top and bottom rails 42 , 44 past the last picket or baluster 46 on both sides.
- FIG. 8 illustrates the preassembled raking rail panel 40 in a straight, square orientation.
- Cutting lines 170 , 172 are illustrated. Cutting along the cutting lines 170 , 172 leaves rail extensions an equal distance from an adjacent baluster 46 .
- a mountable rail end 176 of the bottom rail 44 is equal in distance to a mountable rail end 178 of the bottom rail 44 is equal in distance to a mountable rail end 180 of the top rail 42 is equal in distance to a mountable rail end 182 of the top rail 42 .
- measuring and cutting the preassembled rail panel 40 for a specific installation is significantly simplified.
- the raking rail panel in its original six or eight foot length may fit the installation, and therefore no cutting is required.
- FIG. 9 illustrates the cut rail panel 40 in a raked configuration in position and held by the adjustable bracket assemblies 60 , 62 , 64 , 66 .
- Each of the balusters 46 is coupled to the top rail 42 at respective aligned pivot axes and to the bottom rail 44 at respective aligned pivot axes.
- Dropping-in the raked rail panel 40 is enabled because the pivot axis of the rail support brackets 130 , 150 are aligned with the pivot axes of the balusters.
- pivoting of the adjustable bracket assemblies 60 , 62 , 64 , 66 can be done simultaneous with pivoting of the raking rail panel 40 . This enables virtually automatic pivot adjustment to accommodate the rake angle.
- top and bottom rails 42 , 44 of the preassembled cut rail panel 40 are received through the countersunk holes in the side walls of the cups 132 , 152 .
- Self-taping metal screws are used to such that the screws engage the walls of the top and bottom rails 42 , 44 .
- Pilot holes may be drilled before screwing the self-taping screws.
- the countersunk holes may be used as guides for marking and or drilling the pilot holes.
- FIGS. 7 A- 7 D illustrate the caps 190 in an exploded view from the rail support brackets 130 , 150 .
- FIG. 9 illustrates the caps 190 snap-fit to the rail support brackets 130 , 150 to cover the end of the top and bottom rails 42 , 44 .
- the caps 190 are fitted over the end of the top and bottom rails 42 , 44 and over the cups 132 , 152 to conceal the fasteners and complete the aesthetically pleasing rail panel with simplified manufacturing and installation according to the teachings of the present disclosure.
- the caps 190 snap fit to create flush surfaces with the extended post bracket 100 and the short post bracket 70 that appear continuous.
- An example cap or cover 190 is shown and described in U.S. Pat. No. 9,322,180, which is hereby incorporated by reference.
- the cap 190 serves as a cover to hide the countersunk holes 142 , 162 and screws received therethrough to secure the received end of the railing (not shown).
- the cap 190 accordingly provides an aesthetically pleasing finished railing assembly covering the included attachment hardware.
- the cap 190 is made of any suitable material including molded plastic or stamped sheet metal or a metal casting, such as aluminum. If made of stamped sheet metal, the stamped structure of the cap 190 comprises a generally elongate-shape that is folded along two lines to present three adjacent sides of a U-shaped structure.
- the use of the cap 190 presents an installation with no visible fasteners. This also allows the cut ends of a railing, panel or other structure to be hidden along with the spaces that would exist between bracket and rails.
- the cap further has a “snap fit” assembly that locks securely in place with no need for fasteners, adhesive, welding or anything else.
- the cap can further be used from the top of the cup on installations without a wood top cap (over the railing) and from the bottom for installations with a wood top cap.
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Abstract
A raking rail panel system includes a raking rail panel that is supported by four pivotable bracket assemblies. Each pivotable bracket assembly includes a rail support bracket that is hinged to a post bracket. Each post bracket is configured to be coupled to a vertical support post. The post brackets each include a gap filling portion that extends from a mounting face of the vertical support posts. The gap filling portions are sized to either fill a long or a short gap between an end baluster and the vertical support post. The four pivotable bracket assemblies facilitate drop-in installation of the rail panel pivoted in a range of rake angles.
Description
- This application is a continuation of, and claims the benefit of, U.S. patent application Ser. No. 17/826,668, filed on May 27, 2022, which is a continuation of, and claims the benefit of, U.S. patent application Ser. No. 16/722,309, filed on Dec. 20, 2019, now U.S. Pat. No. 11,346,110, issued on May 31, 2022, which is a continuation of, and claims the benefits of, U.S. patent application Ser. No. 15/790,814, entitled “Raking Rail Panel and Bracket System and Method,” filed on Oct. 23, 2017, and naming Evan Timmons as inventor, now U.S. Pat. No. 10,513,854, issued on Dec. 24, 2019, the contents of each of which are hereby incorporated herein by reference.
- The present disclosure relates to construction materials, and more particularly to a rail panel and bracket system that is easily installed in a range of rake angles.
- Conventional raked or raking (sometimes referred to as racked or racking) rail panels are difficult to install and often require more than one person. According to some conventional raking rail panels, the pivot point of the rail bracket is not aligned with the pivot point of the balusters. This frustrates angle adjustability for a pre-assembled rail panel because the angle of the brackets and the angle of the rail panel are not simultaneously adjustable. Thus, precise measuring and prepositioning is required to ensure that the installation properly accounts for a slope of the stairway (i.e. rake angle).
- Reference is made to
FIG. 1A , which illustrates installation of a conventionalraking rail panel 10 on astairway 12. Therail panel 10 includes atop rail 14 and abottom rail 16 separated bybalusters 18. Thebalusters 18 are collectively pivotable with respect to thetop rail 14 and thebottom rail 16. It is important for a professional looking installation that the rail panel appear to be centered within the elevatedvertical support post 20 a and the descendedvertical support post 20 b. Thus, thehorizontal distance 22 from the elevatedvertical support post 20 a to anadjacent baluster 18 should equal thehorizontal distance 24 from the descendedvertical support post 20 b to anadjacent baluster 18. - It is also important that the balusters are parallel to the vertical support posts. The geometry that arises when raked top and bottom rails intersect a support post complicates installation because the top and bottom rails are cut with unequal lengths of mountable extension portions as measured from an adjacent baluster. To accurately measure such unequal lengths, it is often necessary to preposition the panel on a set of
support blocks 26 and mark the top and bottom rails for cutting. Prepositioning the panel is cumbersome and may even result in damage to the rail panel and also possibly to the vertical support posts. -
FIG. 1B shows the raking rail panel in a straight or square configuration with cutting marks that arise when the prepositioned panel is marked.Cutting marks end baluster 18 on the cut rail panel;cutting marks end baluster 18 on the cut rail panel.FIG. 1C shows thecut panel 30 in a raked configuration. The panel is cut such thatmountable extension lengths bottom rails mountable extension lengths bottom rails FIG. 1C that if the top and bottom rails were cut such that themountable extension lengths end balusters 18 and the vertical support posts 20 a, 20 b would need to be filled. - An alternative that avoids prepositioning of a preassembled rail panel requires prepositioning of the top and bottom rails. Once the top and bottom rails are prepositioned, measured, marked, and cut, as described above, the balusters may be installed in a vertical orientation between the top and bottom rails.
- Embodiments of the present disclosure include a raking rail panel system. The system includes a raking rail panel supported by four pivotable bracket assemblies. Each pivotable bracket assembly includes a rail support bracket that is hinged to a post bracket. Each post bracket is configured to be coupled to a vertical support post. The post brackets each include a gap filling portion that extends from a mounting face of the vertical support posts. The gap filling portions are sized to either fill a long or a short gap between an end baluster and the vertical support post. The four pivotable bracket assemblies facilitate drop-in installation of the rail panel pivoted in a range of rake angles.
- A method for installing a raking rail panel includes positioning a first pivotable bracket assembly on a face of an elevated vertical support post. A second pivotable bracket assembly is positioned on a descended vertical support post. A distance between the first and second pivotable bracket assemblies is measured, and then marked on a top rail and a bottom rail. The top and bottom rails are cut to have equal mounting extension lengths. The cut bottom rail is dropped in to the first and second pivotable bracket assemblies.
- Technical advantages of embodiments of the raking rail panel system and method according to the teachings of the present disclosure include accommodation of a range of rake angles by the pivotable bracket assemblies. The bracket assemblies close a gap that would otherwise result if the top and bottom rails were cut to have four equal extension lengths. In addition, measuring and marking is performed without requiring prepositioning of the uncut raking rail panel, so one person can easily install a raking rail panel on a staircase.
- Other technical advantages will be readily apparent to one of ordinary skill in the art from the following figures, descriptions, and claims. Moreover, while specific advantages have been described above, various embodiments may include all, some, or none of the enumerated advantages.
- A more complete understanding of the present invention may be acquired by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein:
-
FIG. 1A-1C illustrate steps of an installation of a prior art raking rail panel; -
FIG. 2 illustrates early steps in an installation of a raking rail panel and gap filling pivotable bracket assemblies according to the teachings of the present disclosure; -
FIGS. 3A-3B are an isometric view and an elevation view of a short post bracket; -
FIGS. 4A-4B are an isometric view and an elevation view of an extended post bracket; -
FIG. 5 is an isometric view of a bottom rail support bracket; -
FIG. 6 is an isometric view of a top rail support bracket; -
FIGS. 7A-7D illustrate embodiments of pivotable bracket assemblies used to support a raking rail panel according to the teachings of the present disclosure; -
FIG. 8 illustrates a step in a process of installing a raking rail panel according to the teachings of the present disclosure; and -
FIG. 9 illustrates a raking rail panel installed in pivotable bracket assemblies according to the teachings of the present disclosure. -
FIG. 2 illustrates a step in the installation of a raking rail panel 40 (seeFIG. 9 ). With reference toFIG. 9 , the rakingrail panel 40 is preassembled and includes atop rail 42 and abottom rail 44 vertically spaced apart from thetop rail 42.Balusters 46, also known as uprights or pickets, extend between the top andbottom rails balusters 46 are horizontally spaced apart and collectively form the barrier portion of therail panel 10. Each of thebalusters 46 is pivotally coupled to the top andbottom rails bottom rails staircase 48, while thebalusters 46 pivot to stay vertical. - The
rail panel 40 is configured for easy installation in a raked configuration according to the teachings of the present disclosure. According to one embodiment, the rakedrail panel 40 is installed as a rail barrier for astairway 48. The rakedrail panel 40 may be installed in sloping configurations common to stairways. As described further below, the installer will cut thepreassembled rail panel 40 to the precise length required for thepreassembled rail panel 40 to fit and be supported by an elevatedvertical support post 50 and a descendedvertical support post 52. More specifically, the pivotable bracket assemblies according to the teachings of the present disclosure support drop-in installation of the cutpreassembled rail panel 40. - The
pivotable bracket assemblies rail panel 40. This is a significant advantage for the installer as it allows the installer set the vertical post members, install the brackets, and then drop the railing, panel or other structure, for example a railing where cables form the primary barrier, into place. This also supports installation with the use of fewer personnel and with an easier and quicker installation and assembly time. - The
preassembled rail panel 40 may be any suitable length. For example, in one embodiment the preassembled rail panel is approximately six feet in length, and in an alternate embodiment, the preassembled rail panel is approximately eight feet in length. - As explained in further detail below, an installer may measure a length of the preassembled rail panel that corresponds to a distance between faces of vertical support posts that are attached to the
stairway 48, the top andbottom rails preassembled rail panel 40 is then dropped into pivotable bracket assemblies that have been previously attached to the vertical support posts 50, 52. A mountable extension of thetop rail 42 extends the same length from anadjacent baluster 46 as a mountable extension of abottom rail 44. - Referring back to
FIG. 2 , the descendedvertical support post 52 is secured to a lower stair of thestairway 48, and a second, elevatedvertical support post 50 is secured to an upper stair of thestairway 48 that is elevated from the lower stair. A base of eachsupport post stairway 48. The posts may be of any suitable metal, for example galvanized steel or aluminum. According to an alternate embodiment, the posts may be made of wood or a durable polymer material. - A pair of pivotable bracket assemblies is mounted to each
vertical support post bottom assembly 60, a descendedbottom assembly 62, an elevated,top assembly 64, and a descended,top assembly 66. Thepivotable bracket assemblies bottom rails bottom rails rail panel 40. For example, the rakingrail panel 40 is pivotable to accommodate rake angles θ in a range of 0-45 degrees. The pivotable bracket assemblies are pivotable to accommodate rake angles θ in a range of 29-40 degrees measured from horizontal, which allows installation on stairways with gradual or steeper slopes. - According to the teachings of the present disclosure, each pivtoable bracket assembly includes two components coupled together by a hinge. Manufacturing of the
pivotable brackets system 10 is manufactured with four separate bracket parts, with two of each provided in a kit along with instructions to install the raking rail panel. - In an early step in the installation of the raked
rail panel 40, a long straight two-by-four piece of wood is positioned on the stairway such that its wide face contacts the upper most edge of each stair. This establishes the slope of the stairway. Marks are made on interior faces of the vertical support posts 50, 52 to mark the location of the lowerpivotable bracket assemblies bottom rail 44. - On the elevated
vertical post 50 drill locations associated with a short gap fillingpost bracket 70 are marked for thepivotable bracket assembly 60. Reference is made toFIGS. 3A and 3B , which are an isometric view and a side, elevation view of the gap fillingpost bracket 70. The gap fillingpost bracket 70 may be referred to a short post bracket because it is shorter to fill a shorter gap distance between the face of the elevatedvertical support post 50 and the end of thebottom rail 44, unlike a extended gap fillingpost bracket 100, which fills a larger gap distance between the end of thetop rail 42 and the face of the elevatedvertical support post 50. - The
short post bracket 70 includes a generally flatrear mounting surface 72 that contacts the mounting face of thevertical support post hole 74 receives a fastener to secure theshort post bracket 70 to thevertical support post hole 74 is countersunk to ensure that the head of the mounting screw is flush. The flush head of the mounting screw does not interfere with the arm of the rail support bracket. - A second fastener is received through an
outer slot 76. Theslot 76 allows adjustment of an angle of theshort post bracket 70 to ensure it is vertical and aligned with thevertical support post slot 76 is formed through anarcuate flange 78 or tab. A body of theshort pivotable bracket 70 defines a pivotarm receiving cavity 80. Thearm receiving cavity 80 is defined by afloor surface 82 and a pair ofsidewalls 84 disposed on opposite sides of thefloor surface 82. Thearm receiving cavity 80 receives an arm portion of a rail support bracket (shown and described below with respect toFIGS. 5 and 6 ) and allows the rail support bracket to pivot in one angular direction, but pivoting in the opposite angular direction is constrained by thefloor surface 82. - A
hinge hole 86 extends through the body. Thehinge hole 86 receives abarrel 88 at one end and ascrew 90 is received in the other end of thehinge hole 86 and threadedly engages the barrel 88 (seeFIGS. 7A and 7D ). Thebarrel 88 is a bearing surface that supports pivoting of the rail support bracket with respect to the fixed short gap fillingpost bracket 70. The body also includes anarcuate surface 92 that corresponds to an arcuate surface of the rail support bracket, as described with respect toFIGS. 5 and 6 . Alength 94 that the body extends from therear mounting face 72 may be in a range of 1-2 inches, for example approximately 1.77 inches. A height of the mountingface 72 may be in a range of 1-4 inches, for example approximately 2.68 inches. These dimensions ensure that the short gap fillingpost bracket 70 fills the short gap between a face of thevertical support post bottom rails - The short gap filling
post bracket 70 is formed by die casting metal, such as aluminum or steel, and machining the die cast aluminum or steel. According to one embodiment, the short gap fillingpost bracket 70 is formed by die casting an aluminum alloy, forexample ADC 12, and machining the cast structure to form the illustrated features. Alternatively, the short gap fillingpost bracket 70 may be formed by molding a durable polymeric material. - Returning briefly to
FIG. 2 , at the descendedvertical support post 52 drill locations associated with an extended or long gap fillingpost bracket 100 are marked. Reference is made toFIGS. 4A and 4B , which are an isometric view and a side, elevation view of the extended gap fillingpost bracket 100. The gap fillingpost bracket 100 may be referred to a long post bracket because it is longer to fill a larger gap distance between the face of the lowervertical support post 52 and the end of thebottom rail 44, unlike the short gap fillingpost bracket 70, which fills the shorter gap distance. - The
extended post bracket 100 includes a generally flatrear mounting surface 102 that contacts the mounting face of thevertical support post hole 104 receives a fastener to secure theextended post bracket 100 to thevertical support post hole 104 is countersunk to ensure that the head of the mounting screw is flush. The flush head of the mounting screw does not interfere with the arm of the rail support bracket. A second fastener is received through anouter slot 106 formed in anarcuate flange 108 or alternatively a tab. Theslot 106 allows adjustment of an angle of theextended post bracket 100 to ensure it is vertical and aligned with thevertical support post pivotable bracket 100 defines a pivotarm receiving cavity 110. Thearm receiving cavity 110 is defined by afloor surface 112 and a pair ofsidewalls 114 disposed on opposite sides of thefloor surface 112. Thearm receiving cavity 110 receives the arm portion of the rail support bracket (described and shown below with respect toFIGS. 5 and 6 ) and allows the rail support bracket to pivot in one angular direction, but pivoting in the opposite angular direction is constrained by thefloor surface 112. Ahinge hole 116 extends through the body. Thehinge hole 116 receives abarrel 88 at one end and ascrew 90 is received in the other end of thehinge hole 116 and threadedly engages the barrel 88 (seeFIGS. 7B and 7C ). Thebarrel 88 is a bearing surface that supports pivoting of the rail support bracket with respect to the fixed extended gap fillingpost bracket 100. - The body also includes an
arcuate surface 118 that corresponds to an arcuate surface of the rail support bracket, as described with respect toFIGS. 5 and 6 . Referring back toFIGS. 4A and 4B , thearcuate surface 118 transitions to aslanted surface 120 that is delimited by therear mounting surface 102. Theslanted surface 120 is generally aligned with a top surface of either the top orbottom rail rear mounting face 102 may be in a range of 2-3 inches, for example approximately 2.28 inches. A height of the mounting face may be in a range of 2-5 inches, for example approximately 3.41 inches. These dimensions ensure that the extended gap fillingpost bracket 100 fills the larger gap between a face of thevertical support post bottom rails - The extended gap filling
post bracket 100 is formed by die casting metal, such as aluminum or steel, and machining the die cast aluminum or steel. According to one embodiment, the extended gap fillingpost bracket 100 is formed by die casting an aluminum alloy, forexample ADC 12, and machining the cast structure to form the illustrated features. Alternatively, extended gap fillingpost bracket 100 may be formed by molding a durable polymeric material. - Referring again to
FIG. 2 , drill locations corresponding to the center throughhole 104 andouter slot 106 of theextended post bracket 100 are marked on the elevated vertical support post 50 a predetermined distance above the drill locations of theshort post bracket 70. The extended post bracket is inverted such that theslot 106 is disposed closest to the lower/short post bracket 70. According to one embodiment, the mark for the center throughhole 104 corresponds to a height of the preassembledraking rail panel 40. According to one embodiment, the height of thepreassembled rail panel 40 is approximately 29.5 inches. According to an alternate embodiment, the preassembledraking rail panel 40 has a height of 35.5 inches. This disclosure contemplates any suitableheight rail panel 40. Regardless of the height of the preassembledraking rail panel 40, if the height is known, the marking for the locations of the upperpivotable post brackets rail panel 40 and thepivotable bracket assemblies - Reference is made to
FIG. 5 , which is an isometric view of arail support bracket 130 configured to support thelower rail 44 of thepreassembled rail panel 40. The lowerrail support bracket 130 includes arail support cup 132 sized to receive an end of thebottom rail 44. Apivot arm 134 extends from a rear of thecup 132. A portion supporting anarcuate surface 135 also extends from the rear of thecup 132. - The bottom
rail support bracket 130 is formed by die casting metal, such as aluminum or steel, and machining the die cast aluminum or steel. According to one embodiment, the bottomrail support bracket 130 is formed by die casting an aluminum alloy, forexample ADC 12, and machining the cast structure to form the illustrated features. Alternatively, the bottomrail support bracket 130 may be formed by molding a durable polymeric material. - The bottom
rail support bracket 130 includes four adjacent sides of a cube-like structure with openings in the top and the front of the cube-like structure to allow an end of thebottom rail 44 to be dropped into thecup 132. The four adjacent sides of thecup 132 comprise a bottom wall orfloor 136, a pair ofopposed side walls 138, and a rear/back wall 140. The pair ofopposed side walls 138 andback wall 140 extend perpendicularly from thebottom wall 136. - The
bottom wall 136 provides a primary support for receiving the end of thebottom rail 44. The weight of thebottom rail 44 and any downward force on thebottom rail 44 is opposed, at least in part, by thebottom wall 136. - The
side walls 138 provide for lateral retention of the received end of thebottom rail 44. At least one of theside walls 138, and in the illustrated embodiment bothside walls 138, includes at least onecountersunk hole 142, for example two countersunkholes 142. Theholes 142 support insertion of a mounting screw through thehole 142 for attachment to a side of thebottom rail 44. This attachment may be made into and through the side of thebottom rail 44 member (using an opening therein) or alternatively against the side surface of the bottom rail 44 (such as with the use of a set screw or self-tapping screw). Thus, using theholes 142 and associated mounting screws, theside walls 138 further function to restrain longitudinal movement of the received bottom rail 44 (i.e., removal of the end of the bottom rail from the cup 132). Thebottom rail 44 may be sufficiently secured within thecup 132 with a fastener received through only one countersunk hole perside wall 138. - The
pivot arm 134 extends from the cup at a non-perpendicular angle. At a distal end of thearm 134, a throughhole 144 is formed. The throughhole 144 receives thebarrel 88 of the hinge assembly when therail support bracket 130 is coupled to the short orextended post bracket pivot arm 134 includes atop surface 146 and abottom surface 148. When thebottom surface 148 contacts thefloor surface cavity post bracket top surface 146 is generally flush with thepost bracket pivot arm 134 is configured to pivot away from contact with thefloor surface post bracket bottom rails stairway 48. According to some embodiments, thepivotable brackets raking rail panel 40 adjusts to accommodate an angle between 29-40 degrees from horizontal. - The portion that includes the
arcuate surface 135 is disposed below thepivot arm 134 and proximate thefloor 136 of thecup 132. Thearcuate surface 135 corresponds to thearcuate surfaces extended post brackets - Reference is made to
FIG. 6 , which illustrates arail support bracket 150 configured to support an upper ortop rail 42 of thepreassembled rail panel 40. The toprail support bracket 150 includes arail support cup 152 sized to receive an end of thetop rail 42. Apivot arm 154 extends from a rear of thecup 152. A portion supporting anarcuate surface 155 also extends from the rear of thecup 152. - The top
rail support bracket 150 is formed by die casting metal, such as aluminum or steel, and machining the die cast aluminum or steel. According to one embodiment, the toprail support bracket 150 is formed by die casting an aluminum alloy, forexample ADC 12, and machining the cast structure to form the illustrated features. Alternatively, the toprail support bracket 150 may be formed by molding a durable polymeric material. - The top
rail support bracket 150 includes four adjacent sides of a cube-like structure with openings in the top and the front of the cube-like structure with openings in the top and the front of the cube-like structure to allow an end of thetop rail 42 to be dropped into thecup 152. The four adjacent sides of thecup 152 comprise a bottom wall orfloor 156, a pair ofopposed side walls 158, and a rear/back wall 160. The pair ofopposed side walls 158 andback wall 160 extend perpendicularly from thebottom wall 156. - The
bottom wall 156 provides a primary support for receiving the end of thetop rail 42. The weight of thetop rail 42 and any downward force on thetop rail 42 is opposed, at least in part, by thebottom wall 156. - The
side walls 158 provide for lateral retention of the received end of thetop rail 42. At least one of theside walls 158, and in the illustrated embodiment bothside walls 158, includes at least onecountersunk hole 162, for example two countersunkholes 162. Theholes 162 support insertion of a mounting screw through thehole 162 for attachment to a side of thetop rail 42. This attachment may be made into and through the side of the top rail 42 (using an opening therein) or alternatively against the side surface of the top rail 42 (such as with the use of a set screw or self-tapping screw). Thus, using theholes 162 and associated mounting screws, theside walls 158 further function to restrain longitudinal movement of the received top rail 42 (i.e., removal of the end of the bottom rail from the cup 152). Thetop rail 42 may be sufficiently secured within thecup 152 with a fastener received through only one countersunk hole perside wall 158. - The
pivot arm 154 extends from thecup 152 at an angle. At a distal end of thearm 154, a throughhole 164 is formed. The throughhole 164 receives thebarrel 88 of the hinge assembly when therail support bracket 150 is coupled to the short orextended post bracket pivot arm 154 includes atop surface 166 and abottom surface 168. When thebottom surface 168 contacts thefloor surface cavity post bracket top surface 166 is generally flush with thepost bracket pivot arm 154 is configured to pivot away from contact with thefloor surface post bracket bottom rails stairway 48. According to some embodiments, thepivotable brackets raking rail panel 40 adjusts to accommodate an angle between 29-40 degrees from horizontal. - The top
rail support bracket 150 is similar to the bottomrail support bracket 130 with the exception of the location of alever arm 154 and thehinge hole 164 formed in thelever arm 154 with respect to afloor surface 156 of thecup 152. Thepivot arm 154 is located below thearcuate surface 155 proximate thefloor 156 of thecup 152. - Although the top
rail support bracket 150 is formed from a different casting than the bottomrail support bracket 130, the bottomrail support bracket 130 is similar to the toprail support bracket 150 with the exception of the location of the respective floor surfaces 136, 156. Thus, in manufacturing, the bottomrail support bracket 130 can be transformed into the top rail support bracket by relocating the floor surface from a bottom portion of the cube-like structure to the top portion of the cube like structure. - The rail support brackets may be stamped or otherwise marked with an indicator, such as a letter “B,” indicating that the bracket is to be used to support the
bottom rail 44 or a “T” to indicate that the bracket is to be used to support the top rail. Similarly, an “S” may be stamped or otherwise marked in theshort post bracket 70, and an “L” may be stamped or otherwise marked in the extended (i.e. long)post bracket 100. - Reference is made to
FIGS. 7A-7D along withFIG. 2 , the pivotable bracket assemblies are coupled to the elevated and descended vertical support posts 50, 52 in position to hold thetop rail 42 andbottom rail 44.FIG. 7A is an isometric, exploded view of the elevated,bottom assembly 60, which includes theshort post bracket 70 hinged to the bottomrail support bracket 130, with thepost mounting slot 76 of theshort post bracket 70 oriented upward.FIG. 7B is an isometric, exploded view of the descendedbottom assembly 62, which includes the extendedpost bracket 100 hinged to the bottomrail support bracket 130 with thepost mounting slot 106 of theextended post bracket 100 oriented upward.FIG. 7C is an isometric, exploded view of the elevated,top assembly 64, which includes the extendedpost bracket 100 hinged to the toprail support bracket 150 with thepost mounting slot 106 of theextended post bracket 100 oriented downward.FIG. 7D is an isometric, exploded view of the descended,top assembly 66, which includes theshort post bracket 70 hinged to the toprail support bracket 150 with thepost mounting slot 76 of theshort post bracket 70 oriented downward. - The floor surfaces 136, 156 of each
cup rear walls side walls bottom rails cups post brackets bottom rails pivotable brackets - A
measurement 169 is made at the rake angle θ from therear wall 140 of the elevated,bottom assembly 60 to therear wall 140 of the descendedbottom assembly 62 is taken. Thismeasurement 169 can be marked on thetop rail 42 and thebottom rail 44. The top and bottom rails are marked to leave at least 1 and ⅜ inches of each of the top andbottom rails baluster 46 on both sides. - Reference is made to
FIG. 8 , which illustrates the preassembledraking rail panel 40 in a straight, square orientation. Cuttinglines lines adjacent baluster 46. In other words, amountable rail end 176 of thebottom rail 44 is equal in distance to amountable rail end 178 of thebottom rail 44 is equal in distance to amountable rail end 180 of thetop rail 42 is equal in distance to amountable rail end 182 of thetop rail 42. Thus, measuring and cutting thepreassembled rail panel 40 for a specific installation is significantly simplified. In should be noted, that in certain rail panel installations, the raking rail panel in its original six or eight foot length may fit the installation, and therefore no cutting is required. -
FIG. 9 illustrates thecut rail panel 40 in a raked configuration in position and held by theadjustable bracket assemblies balusters 46 is coupled to thetop rail 42 at respective aligned pivot axes and to thebottom rail 44 at respective aligned pivot axes. Dropping-in the rakedrail panel 40 is enabled because the pivot axis of therail support brackets adjustable bracket assemblies rail panel 40. This enables virtually automatic pivot adjustment to accommodate the rake angle. - Upon placement of the top and
bottom rails cut rail panel 40 into thecups cups bottom rails -
FIGS. 7A-7D illustrate thecaps 190 in an exploded view from therail support brackets FIG. 9 illustrates thecaps 190 snap-fit to therail support brackets bottom rails caps 190 are fitted over the end of the top andbottom rails cups caps 190 snap fit to create flush surfaces with theextended post bracket 100 and theshort post bracket 70 that appear continuous. An example cap or cover 190 is shown and described in U.S. Pat. No. 9,322,180, which is hereby incorporated by reference. - The
cap 190 serves as a cover to hide the countersunkholes cap 190 accordingly provides an aesthetically pleasing finished railing assembly covering the included attachment hardware. Thecap 190 is made of any suitable material including molded plastic or stamped sheet metal or a metal casting, such as aluminum. If made of stamped sheet metal, the stamped structure of thecap 190 comprises a generally elongate-shape that is folded along two lines to present three adjacent sides of a U-shaped structure. - The use of the
cap 190 presents an installation with no visible fasteners. This also allows the cut ends of a railing, panel or other structure to be hidden along with the spaces that would exist between bracket and rails. The cap further has a “snap fit” assembly that locks securely in place with no need for fasteners, adhesive, welding or anything else. The cap can further be used from the top of the cup on installations without a wood top cap (over the railing) and from the bottom for installations with a wood top cap. When acap 190 is applied to thecups - Although preferred embodiments of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth and defined by the following claims.
Claims (4)
1. A pivotable bracket assembly, comprising:
a post bracket comprising:
a cavity having a cavity floor surface and two cavity side walls each of the cavity side walls having a hinge hole configured to receive a barrel;
a mounting surface; and
a first arcuate surface extending from the mounting surface and forming a gap filling portion; and
a rail support bracket hingedly coupled to the post bracket, the rail support bracket comprising:
a cup having a cup floor and two cup side walls;
a pivot arm extending from a rear of the cup and having a distal through hole configured to receive the barrel when the rail support bracket is coupled to the post bracket; and
a second arcuate surface disposed at the rear of the cup wherein the first pivot arm extends from the second arcuate surface, the second arcuate surface configured to correspond with the first arcuate surface.
2. The pivotable bracket assembly of claim 1 , wherein the cavity is configured to receive the pivot arm such that a bottom surface of the pivot arm contacts the cavity floor surface.
3. The pivotable bracket assembly of claim 1 , wherein the cup is configured to allow a raking rail panel to be dropped into the cup at a non-perpendicular rake angle.
4. The pivotable bracket assembly of claim 1 , further comprising a second, third, and fourth post bracket corresponding with a second, third, and fourth rail support bracket, respectively, the second, third and fourth post brackets having second, third, and fourth gap filling portions, respectively, such that the gap filling portion and the fourth gap filling portion extend a first distance and the second and third gap filling portions extend a second distance greater than the first distance.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US18/186,637 US20230228097A1 (en) | 2017-10-23 | 2023-03-20 | Raking rail panel and bracket system and method |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/790,814 US10513854B2 (en) | 2017-10-23 | 2017-10-23 | Raking rail panel and bracket system and method |
US16/722,309 US11346110B2 (en) | 2017-10-23 | 2019-12-20 | Raking rail panel and bracket system and method |
US17/826,668 US11608643B2 (en) | 2017-10-23 | 2022-05-27 | Raking rail panel and bracket system and method |
US18/186,637 US20230228097A1 (en) | 2017-10-23 | 2023-03-20 | Raking rail panel and bracket system and method |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US17/826,668 Continuation US11608643B2 (en) | 2017-10-23 | 2022-05-27 | Raking rail panel and bracket system and method |
Publications (1)
Publication Number | Publication Date |
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US20230228097A1 true US20230228097A1 (en) | 2023-07-20 |
Family
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Application Number | Title | Priority Date | Filing Date |
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US15/790,814 Active 2038-06-19 US10513854B2 (en) | 2017-10-23 | 2017-10-23 | Raking rail panel and bracket system and method |
US16/722,309 Active 2038-04-03 US11346110B2 (en) | 2017-10-23 | 2019-12-20 | Raking rail panel and bracket system and method |
US17/826,668 Active US11608643B2 (en) | 2017-10-23 | 2022-05-27 | Raking rail panel and bracket system and method |
US18/186,637 Abandoned US20230228097A1 (en) | 2017-10-23 | 2023-03-20 | Raking rail panel and bracket system and method |
Family Applications Before (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/790,814 Active 2038-06-19 US10513854B2 (en) | 2017-10-23 | 2017-10-23 | Raking rail panel and bracket system and method |
US16/722,309 Active 2038-04-03 US11346110B2 (en) | 2017-10-23 | 2019-12-20 | Raking rail panel and bracket system and method |
US17/826,668 Active US11608643B2 (en) | 2017-10-23 | 2022-05-27 | Raking rail panel and bracket system and method |
Country Status (5)
Country | Link |
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US (4) | US10513854B2 (en) |
AU (1) | AU2018355153A1 (en) |
CA (1) | CA3079894A1 (en) |
WO (1) | WO2019083874A1 (en) |
ZA (1) | ZA202002690B (en) |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11136764B2 (en) * | 2018-05-04 | 2021-10-05 | Vinylast, Inc. | Bracket with horizontal and vertical swivel capabilities |
US11692383B2 (en) * | 2018-07-24 | 2023-07-04 | eGlass, LLC | Hinge assembly for elevational rails |
KR102254952B1 (en) * | 2019-06-28 | 2021-05-24 | 이승로 | Coupling structure for crossbar of handrail |
WO2021030917A1 (en) * | 2019-08-22 | 2021-02-25 | Peak Innovations Inc. | Brackets for stair railings |
WO2022035833A1 (en) * | 2020-08-11 | 2022-02-17 | Fiber Composites, Llc | Latching railing arrangement |
WO2023244236A1 (en) * | 2022-06-16 | 2023-12-21 | Fabian Piorno | Privacy picket fence assembly |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5026028A (en) * | 1988-12-19 | 1991-06-25 | Yoshida Kogyo, K. K. | Apparatus for connecting strut and horizontal member |
US5547169A (en) * | 1994-11-10 | 1996-08-20 | The Anchor Group | Fence assembly with swivel bracket |
US6053481A (en) * | 1998-07-28 | 2000-04-25 | Security Fence Manufacturing & Supply Co., Inc. | Security fence rail bracket |
Family Cites Families (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2715513A (en) * | 1953-04-17 | 1955-08-16 | Kools Brothers Inc | Adjustable railing section |
US3767236A (en) * | 1972-03-02 | 1973-10-23 | Blumcraft Pittsburgh | Hinged handrail fitting |
US3960367A (en) | 1975-05-12 | 1976-06-01 | Spacemaker (Products) Limited | Fence with adjustable vertical panels |
JPH05187114A (en) | 1992-01-10 | 1993-07-27 | Sekisui Chem Co Ltd | Handrail for stair |
US6802496B1 (en) * | 2002-12-09 | 2004-10-12 | John Preta | Fence bracket system and fence system using the fence bracket system |
US20060033093A1 (en) * | 2004-08-12 | 2006-02-16 | Chong-Yi Lo | Possible-to-sway fence connector |
US8899555B2 (en) | 2007-09-06 | 2014-12-02 | Fortress Iron, Lp | Adjustable picket fence |
CA2712476A1 (en) | 2008-01-16 | 2009-07-23 | Ken Ferris | Slot rail assembly |
US9322180B2 (en) | 2012-01-10 | 2016-04-26 | Fortress Iron, Lp | Bracket for supporting attachment of the end of a railing member to a vertical member |
US9587414B2 (en) | 2012-09-25 | 2017-03-07 | James A Lachenberg | Fully welded fence panel and method of making same |
US9500000B2 (en) * | 2014-11-21 | 2016-11-22 | James E. McCarty | Fencing panel and method of assembly |
-
2017
- 2017-10-23 US US15/790,814 patent/US10513854B2/en active Active
-
2018
- 2018-10-22 CA CA3079894A patent/CA3079894A1/en active Pending
- 2018-10-22 WO PCT/US2018/056843 patent/WO2019083874A1/en active Application Filing
- 2018-10-22 AU AU2018355153A patent/AU2018355153A1/en active Pending
-
2019
- 2019-12-20 US US16/722,309 patent/US11346110B2/en active Active
-
2020
- 2020-05-12 ZA ZA2020/02690A patent/ZA202002690B/en unknown
-
2022
- 2022-05-27 US US17/826,668 patent/US11608643B2/en active Active
-
2023
- 2023-03-20 US US18/186,637 patent/US20230228097A1/en not_active Abandoned
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5026028A (en) * | 1988-12-19 | 1991-06-25 | Yoshida Kogyo, K. K. | Apparatus for connecting strut and horizontal member |
US5547169A (en) * | 1994-11-10 | 1996-08-20 | The Anchor Group | Fence assembly with swivel bracket |
US6053481A (en) * | 1998-07-28 | 2000-04-25 | Security Fence Manufacturing & Supply Co., Inc. | Security fence rail bracket |
Also Published As
Publication number | Publication date |
---|---|
US20200123782A1 (en) | 2020-04-23 |
US20220290438A1 (en) | 2022-09-15 |
US10513854B2 (en) | 2019-12-24 |
AU2018355153A1 (en) | 2020-05-21 |
CA3079894A1 (en) | 2019-05-02 |
US20190119924A1 (en) | 2019-04-25 |
US11608643B2 (en) | 2023-03-21 |
WO2019083874A1 (en) | 2019-05-02 |
ZA202002690B (en) | 2023-04-26 |
US11346110B2 (en) | 2022-05-31 |
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