Cable Tensioning System

Abstract

A cable rail barrier is provided which includes one or more cables that extend between the two or more posts and a cable tensioning system. The cable tensioning system secures and tensions the at least one cable of the one or more cables to the first post. The cable tensioning system includes a tensioner housing. The tensioner housing is linearly movable in a first direction and a second direction. The tensioner housing includes a tapered housing component. The tensioner housing includes a threaded housing component. A clamp jaw fits into the passageway of the tapered housing component. A spring exerts a bias force on the clamp jaw to bias the clamp jaw in the first direction within the tapered housing component. The spring exerts the bias force on the clamp jaw to provide a grip on the end portion of the at least one cable of the one or more cables. Movement of the tensioner housing in the second direction when the at least one cable of the one or more cables is held by the clamp jaw pulls the at least one cable of the one or more cables taut and tensions the at least one cable of the one or more cables. Movement of the tensioner housing in the first direction causes the tensioner housing to move against the bias force of the spring to allow the at least one cable of the one or more cables to be released from the clamp jaw.

Description

TECHNICAL FIELD AND SUMMARY

The present disclosure relates to railings, fences, and like barriers, and, particularly, to the use of cables employed in such railings, fences, and like barriers.

An illustrative embodiment of the present disclosure provides a cable rail barrier, which includes a top rail that extends between two or more posts, one or more cables that extend between the two or more posts, and a cable tensioning system. At least one cable of the one or more cables is configured to couple to at least a first post of the two or more posts. The at least one cable of the one or more cables is configured to be tensioned to provide a desired amount of rigidity. The cable tensioning system secures and tensions the at least one cable of the one or more cables to the first post. The cable tensioning system includes a cartridge that includes at least one tensioner housing receptacle and a tensioner housing. The cartridge fits into an interior of the first post. The at least one tensioner housing receptacle includes a first channel and a second channel which are open to each other. Between the first channel and the second channel is a first rail component and a second rail component. The first rail component and the second rail component provide a linear path of travel for the tensioner housing, which is movable in a first direction and a second direction. The tensioner housing includes a tapered housing component with a conical tapered edge and a threaded housing component with a threaded inner periphery. The tapered housing component of the tensioner housing fits into the first channel of the at least one tensioner housing receptacle and the threaded housing component of the tensioner housing fits into the second channel of the at least one tensioner housing receptacle. A bearing portion is located between the tapered housing component and the threaded housing component of the tensioner housing to allow linear movement of the tensioner housing in either the first direction or the second direction within the at least one tensioner housing receptacle. A passageway is disposed through the tapered housing component of the tensioner housing. A conical clamp jaw fits into the passageway of the tapered housing component. The conical clamp jaw includes a plurality of opposing jaw parts that form a conically shaped body. A spring exerts a bias force on the conical clamp jaw to bias the conical clamp jaw in the first direction towards the conical tapered edge within the tapered housing component. An end portion of the at least one cable of the one or more cables is extendable through the first post, into the tapered housing component, and fits between the plurality of opposing jaw parts. The spring exerts the bias force on the conical clamp jaw towards the conical tapered edge to provide a grip on the end portion of the at least one cable of the one or more cables. A screw fits into and moves on the threaded inner periphery of the threaded housing component and a tensioner bolt extends through the first post and secures to the screw. Rotation of the tensioner bolt rotates the screw, which causes the tensioner housing to move in either the first direction or the second direction. Movement of the tensioner housing in the second direction when the at least one cable of the one or more cables is held by the conical clamp jaw pulls the at least one cable of the one or more cables taut and tensions the at least one cable of the one or more cables. Movement of the tensioner housing in the first direction causes the tensioner housing to move towards an interior wall of the first post to push the conical clamp jaw against the bias force of the spring to allow the at least one cable of the one or more cables to be released from the conical clamp jaw.

In the above and other embodiments, the cable rail barrier may further comprise: movement of the tensioner housing in the first direction causes the conical clamp jaw to engage the interior wall of the first post which moves the conical clamp jaw with respect to the conical tapered edge to relieve the grip on the at least one cable of the one or more cables; movement of the tensioner housing in the second direction causes the conical clamp jaw to engage the conical tapered edge to apply a force against the at least one cable of the one or more cables to further the grip on the at least one cable of the one or more cables; the at least one tensioner housing receptacle has an inner periphery that substantially conforms to a shape of an outer periphery of the tensioner housing; the screw does not move linearly in either the first direction or the second direction; the cable tensioning system further comprises a backing pin attached to the tapered housing component and engages the spring opposite the conical clamp jaw to direct the bias force on the conical clamp jaw towards the conical tapered edge; the bearing portion is composed of a material selected from the group consisting of plastic and stainless steel; the tensioner housing is composed of a material selected from the group consisting of plastic and stainless steel; the cartridge includes one or more positioning tabs located about a periphery of the cartridge to position the cartridge at a predetermined position within the first post; a second cartridge is located within the first post; and a second tensioner housing receptacle of the at least one tensioner housing receptacle is provided on the cartridge.

Another illustrative embodiment of the present disclosure provides a cable rail barrier, which includes a top rail that extends between two or more posts, one or more cables that extend between the two or more posts, and a cable tensioning system. The at least one cable of the one or more cables is configured to be tensioned to provide a desired amount of rigidity. A cable tensioning system that secures and tensions the at least one cable of the one or more cables to the first post, the cable tensioning system includes a cartridge that has at least one tensioner housing receptacle and a tensioner housing. The cartridge fits into an interior of the first post. The tensioner housing is linearly movable in a first direction and a second direction. The tensioner housing includes a tapered housing component. The tensioner housing includes a threaded housing component. The tapered housing component and the threaded housing component of the tensioner housing fits into the at least one tensioner housing receptacle. A passageway is disposed through the tapered housing component of the tensioner housing. A clamp jaw fits into the passageway of the tapered housing component. A spring that exerts a bias force on the clamp jaw to bias the clamp jaw in the first direction within the tapered housing component. An end portion of the at least one cable of the one or more cables is extendable through the first post and into the tapered housing component. The spring exerts the bias force on the clamp jaw to provide a grip on the end portion of the at least one cable of the one or more cables. A screw fits into and rotates within the threaded housing component, which causes the tensioner housing to move in either the first direction or the second direction. Movement of the tensioner housing in the second direction, when the at least one cable of the one or more cables is held by the clamp jaw, pulls the at least one cable of the one or more cables taut and tensions the at least one cable of the one or more cables. Movement of the tensioner housing in the first direction causes the tensioner housing to move against the bias force of the spring to allow the at least one cable of the one or more cables to be released from the clamp jaw.

In the above and other embodiments, the cable rail barrier may further comprise: movement of the tensioner housing in the first direction causes the tensioner housing to move towards an interior wall of the first post to push the clamp jaw against the bias force of the spring to allow the at least one cable of the one or more cables to be released from the clamp jaw; a tensioner bolt that extends through the first post and secures to the screw, wherein rotation of tensioner bolt rotates the screw, which causes the tensioner housing to move in either the first direction or the second direction; the screw fits into and rotates within a threaded inner periphery of the threaded housing component; the tapered housing component includes a tapered edge, wherein the spring exerts the bias force on the clamp jaw towards the tapered edge to provide the grip on the end portion of the at least one cable of the one or more cables; the clamp jaw is a conical clamp jaw that includes a plurality of opposing jaw parts that form a conically shaped body, and wherein the end portion of the at least one cable of the one or more cables is extendable through the first post, into the tapered housing component, and fits between the plurality of opposing jaw parts; the at least one tensioner housing receptacle includes a first channel and a second channel which are open to each other, wherein between the first channel and the second channel is a first rail component and a second rail component, and wherein the first rail component and the second rail component provide a linear path of travel for the tensioner housing in the first direction and the second direction; and the tapered housing component of the tensioner housing fits into the first channel of the at least one tensioner housing receptacle and the threaded housing component of the tensioner housing fits into the second channel of the at least one tensioner housing receptacle, and wherein a bearing portion is located between the tapered housing component and the threaded housing component of the tensioner housing to allow linear movement of the tensioner housing in either the first direction or the second direction within the at least one tensioner housing receptacle.

Another illustrative embodiment of the present disclosure provides a cable rail barrier which includes one or more cables that extend between the two or more posts and a cable tensioning system. At least one cable of the one or more cables is configured to couple to at least a first post of the two or more posts. The at least one cable of the one or more cables is configured to be tensioned to provide a desired amount of rigidity. A cable tensioning system secures and tensions the at least one cable of the one or more cables to the first post. The cable tensioning system includes a tensioner housing. The tensioner housing is linearly movable in a first direction and a second direction. The tensioner housing includes a tapered housing component. The tensioner housing includes a threaded housing component. A passageway is disposed through the tapered housing component of the tensioner housing. A clamp jaw fits into the passageway of the tapered housing component. A spring that exerts a bias force on the clamp jaw to bias the clamp jaw in the first direction within the tapered housing component. An end portion of the at least one cable of the one or more cables is extendable into the tapered housing component. The spring exerts the bias force on the clamp jaw to provide a grip on the end portion of the at least one cable of the one or more cables. A screw that fits into and rotates within the threaded housing component, which causes the tensioner housing to move in either the first direction or the second direction. Movement of the tensioner housing in the second direction, when the at least one cable of the one or more cables is held by the clamp jaw, pulls the at least one cable of the one or more cables taut and tensions the at least one cable of the one or more cables. Movement of the tensioner housing in the first direction causes the tensioner housing to move against the bias force of the spring to allow the at least one cable of the one or more cables to be released from the clamp jaw.

Additional features of the cable tensioning system will become apparent to those skilled in the art upon consideration of illustrative embodiments of carrying out the cable tensioning system as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The concepts described in the present disclosure are illustrated by way of example and not by way of limitation in the accompanying figures. For simplicity, and clarity of illustration, elements illustrated in the figures are not necessarily drawn to scale. For example, and clarity, the dimensions of some elements may be exaggerated relative to other elements. Further, where considered appropriate, reference labels may be repeated among the figures to indicate corresponding or analogous elements.

FIG. 1 is a side view of a cable barrier;

FIG. 2 is a detail perspective view of a portion of an end post with cables extending therein as part of the cable barrier;

FIG. 3 is an interior elevational view of post;

FIG. 4 is an exploded perspective view of a portion of the post along with a cable tensioner assembly;

FIG. 5 is a detail cross-sectional side view of a portion of the post with a tensioner housing fitted within the tensioner housing receptacle;

FIG. 6 is another detail cross-sectional side view of a portion of the post with the tensioner housing fitted within the tensioner housing receptacle;

FIG. 7 is another detail cross-sectional side view of a portion of the post with the tensioner housing fitted within the tensioner housing receptacle;

FIG. 8 is another detail cross-sectional side view of a portion of the post with the tensioner housing fitted within the tensioner housing receptacle;

FIG. 9 is another detail cross-sectional side view of a portion of the post with the tensioner housing fitted within the tensioner housing receptacle;

FIG. 10 is another detail cross-sectional side view of a portion of the post with the tensioner housing fitted within the tensioner housing receptacle; and

FIG. 11 is a detail perspective view of the portion of the end post with cables extending therein.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates embodiments of the cable tensioning system, and such exemplification is not to be construed as limiting the scope of the cable tensioning system in any manner.

DISCLOSURE OF ILLUSTRATIVE EMBODIMENTS

The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described devices, systems, and methods, while eliminating, for the purpose of clarity, other aspects that may be found in typical devices, systems, and methods. Those of ordinary skill may recognize that other elements and/or operations may be desirable and/or necessary to implement the devices, systems, and methods described herein. Because such elements and operations are well known in the art, and because they do not facilitate a better understanding of the present disclosure, a discussion of such elements and operations may not be provided herein. However, the present disclosure is deemed to inherently include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the art.

An illustrative embodiment of the present disclosure provides a cable rail barrier composed of a top rail extending between two or more posts. One or more cable rails may extend between the two or more posts. In some embodiments, multiple cable rails may be located periodically along the height of the post to form the barrier. In some embodiments, the cable rails may be affixed to a first end post, and extend through one or more intermediate posts and affixed to a second end post. Each cable is configured to couple to either or both the first and second end posts. Each cable is also configured to be tensioned to provide a desired amount of rigidity.

In order to secure and tension each cable rail to either or both the first and second posts, a cartridge may be positioned inside of the post with a tensioner housing receptacle aligned with a cable hole disposed through the post wall at the particular desired height for the cable rail. A bolt hole may be located adjacent the cable hole and also aligned with the tensioner housing receptacle. The tensioner housing receptacle is configured to receive a tensioner housing that is movable within the tensioner housing receptacle toward and away from the cable and bolt holes disposed through the post wall. An illustratively partially conical clamp, with split jaws, is located in a tapered housing component of the tension housing. The tapered housing includes a partially conically shaped tapered portion located adjacent its leading end. The partially conically shaped tapered portion is complementary to the conical shape of the clamp. This is so that as the clamp extends further into the tapered portion of the tapered housing component the jaws of the clamp will move into a closed direction. A cable can be inserted through the cable hole in the post and into the clamp to be held and tensioned.

The tensioner housing also includes a threaded housing component that receives a screw. The screw is sized and configured to rotate within the tapered housing component and cartridge without substantially moving laterally. Instead, by rotating the screw, the tapered housing component and, thus, the tensioner housing is longitudinally movable within the cartridge toward and away from the post wall. Rotating the screw in one direction moves the tensioner housing away from the cable hole, whereas rotating the screw in the opposite direction moves the tensioner housing towards the cable hole. A tensioner or shoulder bolt extends through the bolt hole located adjacent the cable hole and is configured to secure to the screw. Using the shoulder bolt and bolt hole provides access to the screw. Rotating the shoulder bolt in one direction rotates the screw in that same direction, which moves the tensioner housing away from the cable hole. Conversely, rotating the shoulder bolt in the opposite direction rotates the screw in the opposite direction, thereby moving the tensioner housing towards the cable hole. This allows a drill, wrench, or screwdriver to rotate the shoulder bolt and, thus, the screw, from exterior of the post. Accordingly, the cable can be extended into the clamp and then, by rotating the shoulder bolt, the tension housing, which holds the clamp, moves away from the cable hole, thereby tensioning the cable.

Illustratively, a spring can be held in the tapered housing component to bias the clamp towards the tapered end of the tapered housing component so the clamp is consequently held in a clamped position. However, when it is desired for the cable to be loosened or released, rotating the screw such that the tensioner housing moves in the opposite direction and adjacent the cable hole of the post, the clamp will be pushed backwards by the interior of the post wall opposite the bias of the spring. This moves at least a portion of the clamp from the partially conical portion of the tapered end of the tapered housing component, which allows the jaws of the clamp to separate sufficient to release the cable and allow it to be pulled from the clamp and out of the post.

When it is desired to re-tension the cable, it is simply inserted into the cable hole with the clamp located adjacent thereto and at least partially moved from the partially conical portion of the tapered end of the tapered housing component allowing the jaws to be separated sufficient to receive the cable within the clamp. Once this is done, the screw can be rotated, which moves the tensioner housing away from the cable hole. This causes the spring bias to push the clamp towards the partially conical portion of the tapered end of the tapered housing component, which acts on the jaws causing them to clamp onto the cable with increased force. With the conical clamp holding on to the cable while moving with the tensioner housing away from the cable hole, the cable is pulled causing it to tension.

As a result, for an installer, all that needs to occur in order to tension a cable is to rotate the screw, using a drill, for example, in one direction to open the clamp inside the post (if not done already), and insert the cable into the clamp. Then, using the drill again, rotate the shoulder bolt in the opposite direction to cause the clamp to move away from the cable hole, thereby pulling on and tensioning the cable. In other words, once the clamp inside the post is open, the cable is simply inserted into the post and the shoulder bolt rotated to hold and tension the cable. This is believed to be a much simpler installation process than using conventional swage fittings, turnbuckles, or other fastening hardware, for example, known for securing and tensioning cables.

A side view of a cable barrier 2 is shown in FIG. 1. This illustrative embodiment of cable barrier 2 is illustratively composed of a top rail 4 extending between vertically oriented posts 6 and 8. A plurality of cables 10 are vertically spaced apart from each other and extend generally horizontally from post 8 through post 6. It is appreciated that cables 10 can extend as long as needed. It is appreciated in this view that post 8 is an end post where each of cables 10 terminate while post 6 is a pass-through post. Each of cables 10 extend through post 6. Depending on the desired length of cable barrier 2, multiple pass-through posts 6 can be positioned along the barrier line so as to support each of cables 10. Another end post (not shown), like post 8, is located on the other end of cable barrier 2 to define the distal end of cable barrier 2. It is further appreciated that top rail 4 may be secured to posts 6 and 8, via support brackets 12, as illustratively shown.

An issue with cable barriers like this is at the end posts. There is typically some mounting hardware that both attaches the cable to the post and tensions the cable. Unlike rigid balusters, which only need to be attached to a structure like a post or rail, cables require both attachment to the post or rail, as well as tensioning. This tensioning converts the cable from a flexible line to a rigid barrier member. It is this step of tensioning, in addition to attachment, that poses a challenge for cable barriers.

An illustrative embodiment of the present disclosure provides an end post 8 having a hollow core (see, also, FIG. 4) into which each of cables 10 extends. Once cable 10 is held inside post 8, a tensioner bolt 14, located on post 8, and illustratively below each of cables 10, increases or decreases its tension. Accordingly, for the installer, the step of attaching the cable to the post is primarily composed of extending the cable into the opening in the post and rotating tensioner bolt 14. The tensioning step is primarily composed of continuing to rotate tensioner bolt 14 until the desired tension in cable 10 is reached. These steps are repeated for each of the cables 10 that will be used as part of cable barrier 2. It will be appreciated upon reading this disclosure herein that the location of the tensioner bolt, with respect to the cable hole in the post that receives cable 10, is illustrative. Tensioner bolt 14 may be positioned in other locations relative to the cable hole depending on the orientation of other structures that are discussed further herein.

A detail perspective view of a portion of end post 8, with cables 10 extending therein as part of cable barrier 2, is shown in FIG. 2. Tensioner bolts 14 are shown illustratively located underneath corresponding cable holes 16, each receiving a cable 10. Illustratively, tensioner bolts 14 may be shoulder bolts or other types of rotating structures sufficient for this disclosure. In the illustrated embodiment, tensioner bolt 14 includes an Allen head for receiving an Allen wrench to rotate it in either directions 18 or 20. Accordingly, when an installer is ready to install each cable 10, it is inserted into cable hole 16. Tensioner bolt 14 is then rotated illustratively in a clockwise direction (although in other embodiments it may be counterclockwise), which tensions the cable inside post 8. If the installer desires to loosen or remove the cable, tensioner bolt 14 is rotated in the opposite direction 20 counterclockwise (although in other embodiments it may be clockwise), which lessens the tension and releases cable 10 from post 8. These steps can be repeated for each of the cables 10 like those shown in FIG. 2. It is appreciated that the head for tensioner bolt 14 may alternatively be a Phillips, flat, hex, or the like.

An interior elevational view of post 8 is shown in FIG. 3. Like that shown in FIG. 2, tensioner bolts 14, with adjacent cable holes 16, are periodically located along the height of post 8. Cable hole 16 dictates the position on post 8 that cable 10 will be. It is appreciated that such cable holes 16, along with adjacent tensioner bolts 14, may be located anywhere along post 8, so long as it is hollow inside as indicated by hollow post interior 22. Support bracket 12 is shown attached to post 8 for securing top rail 4 thereto.

An exploded perspective view of a portion of post 8, along with cable tensioner assembly 24, is shown in FIG. 4. Components of cable tensioner assembly 24 includes cartridge 26 and tensioner housing 28. Cartridge 26 is sized to fit into hollow post interior 22. Positioning tabs 30 are located about the periphery of cartridge 26 in order to position same at a specific desired location within post 8. One or more tensioner housing receptacles 32 are located within cartridge 26. Illustratively, tensioner housing receptacle 32 may have an inner periphery that generally conforms to the outer periphery of tensioner housing 28. As illustratively shown, tensioner housing receptacle 32 includes a first channel 34 and a second channel 36 having open ends facing each other. At the open ends of first and second channels 34 and 36, respectively, are rail components 38 and 40, which provide a linear path of travel for tensioner housing 28 in directions 42 and 44.

Tensioner housing 28 includes a tapered housing component 46 with a conical tapered edge 48 adjacent the leading edge and a threaded housing component 50. It is appreciated that tapered housing component 46 of tensioner housing 28 fits in first channel 34 of tensioner housing receptacle 32 and threaded housing component 50 fits into second channel 36 of tensioner housing receptacle 32. Bearing portion 52 is located between tapered housing component 46 and threaded housing component 50. It is appreciated that bearing 52, which can be positioned on each side of tensioner housing 28, may be positioned adjacent rail components 38 and 40. It is appreciated that in some embodiments, bearing 52 may have a bearing surface or no bearing surface depending on the makeup of tensioner housing 28 and tensioner housing receptacle 32. For example, the materials of these structures, such as a plastic, stainless steel, or like material, may be sufficient so that tensioner housing 28 can move in directions 42 and 44 within tensioner housing receptacle 32. On the other hand, and if so desired, a bearing material or structure can be part of bearing 52 and/or tapered housing component 46 and/or threaded housing component 50. It will be appreciated by the skilled artisan upon reading this disclosure that tensioner housing 28 can be configured so it will be able to sufficiently move linearly in either directions 42 and 44 within tensioner housing receptacle 32.

A passageway 54 is disposed through tapered housing component 46. Illustrative conical clamp jaws 56 is sized to fit into passageway 54 of tapered housing component 46. Opposing jaw parts 58 and 60 form the generally conically shaped body of conical clamp jaws 56 that terminate at a ridge 62. A spring 64 is configured to act on ridge 62 of conical clamp jaws 56 for purposes of biasing same in direction 42 within tapered housing component 46. Illustratively, a washer 66 may be positioned between spring 64 and conical clamp jaws 56 to assist in allowing spring 64 to bias conical clamp jaws 56 in direction 42. A backing pin 68 is disposed through openings 70 disposed through a rear portion of tapered housing component 46 opposite tapered edge 48. Backing pin 68 is configured to abut spring 64 to direct bias of same in direction 42 in order to be applied onto conical clamp jaws 56. An end portion of cable 10 is configured to extend into tapered housing component 46 and fit between jaw parts 58 and 60 when they are adjacent cable hole 16, as further described herein. Spring 64 will exert a bias force on conical clamp jaws 56 in order to push against it to help maintain a grip on cable 10 until conical clamp jaw 56 is moved, as further described herein, to relieve the clamping force of jaw parts 58 and 60.

How tensioner housing 28 is moved in directions 42 and 44 is determined by screw 72 that fits in and correspondingly moves with respect to the threaded inner periphery of threaded housing component 50. In the illustrated embodiment, screw 72 does not itself move linearly in directions 42 and 44. All it does is rotate. The illustrative tensioner bolt 14 extends through opening 74 disposed through wall 76 of post 8 and secures onto screw 72 illustratively, via threaded bore 78. Accordingly, rotating tensioner bolt 14 rotates screw 72. Such rotation in one direction will cause tensioner housing 28 to move in either direction 42 or 44. Moving tensioner housing 28 in direction 44 when cable 10 is secured onto conical clamp jaw 56 will pull cable 10 taut and tension it. Conversely, rotating tensioner bolt 14 in an opposite direction rotates screw 72 in an opposite direction, thereby causing tensioner housing 28 to move linearly in direction 42, which in this case, is towards the interior of wall 76 of post 8.

Detail cross sectional side views of a portion of post 8, with tensioner housing 28 fitted within tensioner housing receptacle 32, is shown in progression views of FIGS. 5, 6, 7, 8, 9, and 10. These views collectively demonstrate how a cable 10 is inserted into post 8 and tensioned or de-tensioned. The view shown in FIG. 5 includes cable 10 located exterior of cable hole 16 of post 8. Tensioner housing 28 is positioned within tensioner housing receptacle 32 of cartridge 26, which is located within hollow post interior 22 of post 8. Screw 72 is shown disposed within threaded housing component 50, as well as second channel 36 of tensioner housing receptacle 32. When tensioner housing 28 is in this position, abutted against wall 76 of post 8, jaw parts 58 and 60 of conical clamp jaw 56 are pushed back into passageway 54 of tapered housing component 46, against the bias of spring 64. Additionally, because conical clamp jaws 56 are predominantly conically shaped, the narrow part of same is located adjacent tapered edge 48 of tapered housing component 46. This means the least amount of closure force being applied by tapered edge 48 is being applied to jaw parts 58 and 60. The result is that cable 10 can be inserted into cable hole 16 and then between jaw parts 58 and 60.

A detail side cross sectional view of tensioner housing receptacle 32, similar to that shown in FIG. 5, is also shown in FIG. 6. Here, cable 10 is inserted through cable hole 16 and into conical clamp jaws 56. Again, because insufficient clamping force is being applied to jaw parts 58 and 60 at this stage, cable 10 is able to extend therebetween. It is further notable that tensioner housing 28 is still abutted against wall 76 of post 8. It is appreciated that cable 10 can extend further in direction 44 within passageway 54 of tapered housing component 46. All that is necessary is that sufficient room exist within first channel 34 to accommodate tensioner housing 28 to move far enough in direction 44 to tension cable 10. In some backing pin 68 may limit the extent cable 10 can extend into tapered housing component 46.

Another detail side cross sectional view of tensioner housing receptacle 32 of cartridge 26, located in hollow post interior 22 of post 8, is shown in FIG. 7. This view continues that of FIGS. 5 and 6 where cable 10 is further inserted into post 8 in direction 44 so that cable 10 extends beyond conical clamp jaws 56. This view also differs in that tensioner bolt 14 is rotated, illustratively, in direction 18 (see FIG. 2), which moves tensioner housing 28 in direction 44 with respect to tensioner housing receptacle 32. This means the leading edge of tensioner housing 28 no longer abuts wall 76 of post 8. By moving tensioner housing 28 in direction 44, bias from spring 64, pushes conical clamp jaws 56 in direction 42. This causes the wider part of conical clamp jaws 56, particularly jaw parts 58 and 60, to be located within tapered edge 48. When this occurs, more clamping force is applied to jaw parts 58 and 60, which, in turn, applies a greater clamping force against cable 10. The result is that cable 10 is secured in place in conical clamp jaws 56 and is movable in direction 44 as tensioner housing 28 is caused to move by rotating tensioner bolt 14 in order to rotate screw 72. With cable 10 being securely held by conical clamp jaws 56, as tensioner housing 28 is moved in direction 44, so too is cable 10. The effect of this is cable 10 will straighten and tension into a rigid structure as tensioner housing 28 is further caused to move in direction 44 by rotation of screw 72.

Another side detail cross sectional view of tensioner housing receptacle 32, with tensioner housing 28 located therein, is shown in FIG. 8. This view continues from FIG. 7 in that further rotation of screw 72, via rotating tensioner bolt 14, continues to move tensioner housing 28 in direction 44. This causes cable 10 to be pulled further in direction 44, as well. This continual movement of tensioner housing 28, with conical clamp jaws 56 holding on to cable 10, causes the same to be further tensioned. Cable 10 can be tensioned to any desired amount within the range defined by the extent of travel that tensioner housing 28 can achieve within post 8. This view further demonstrates how tapered edge 48 of tapered housing component 46 acts on conical clamp jaws 56, particularly, the widest portion thereof to create a significant clamping force on jaw parts 58 and 60 to hold cable 10 in place and be tensioned. This is further augmented by spring 64 biasing against conical clamp jaws 56, as well as cable 10 itself creating a resistance force in direction 42 while being tensioned in direction 44. This causes conical clamp jaws 56 to move in direction 42, as well, until ridge 62 of conical clamp jaws 56 engages the inner edge of tapered edge 48. Thus, as cable 10 is being tensioned in direction 44, that is causing an increased clamping force against cable 10 to further assist holding it in place. Again, this is accomplished by rotating tensioner bolt 14 illustratively in direction 18 (see FIG. 2), which rotates screw 72 so as to move tensioner housing 28 linearly in direction 44 along the body of screw 72.

If, after cable 10 is positioned and tensioned within tensioner housing 28, as shown in FIG. 8, it is desired to relieve the tension and possibly remove cable 10 from tensioner housing 28, all the installer needs to do is rotate tensioner bolt 14 in the opposite direction, such as direction 20 (see FIG. 2). Rotating tensioner bolt 14 in this opposite direction will likewise rotate screw 72 in this opposite direction as well. The threaded surfaces of screw 72, in threaded housing component 50, will move tensioner housing 28 in direction 42. Doing this will create slack in cable 10.

This movement of housing 28 in direction 42 continues until tensioner housing 28 abuts wall 76. At this point, conical clamp jaws 56 abuts wall 76 as well, so that the narrower part of jaw parts 58 and 60 is back within tapered edge 48 of tapered housing component 46. This means less gripping force is being exerted onto cable 10. This means it is able to move in direction 42, itself, to be removed from conical clamp jaws 56.

As shown in FIG. 10, cable 10 has been removed from conical clamp jaws 56 making cable 10 able to be released from post 8. Because tapered edge 48 of tapered housing component 46 does not exert as much force on the narrow end portions of jaw parts 58 and 60 as it does on the wider end adjacent ridge 62, cable 10 can be removed from conical clamp jaws 56 when tensioner housing 28 is in the position shown. It is appreciated that tensioner housing 28 is movable to the position shown here in FIG. 10 when screw 72 is rotated by tensioner bolt 14 in an illustrative counterclockwise manner.

This process from FIGS. 5-10 can be repeated again for each of cables 10 being attached to post 8. Illustratively, tensioner housing 28 can be reset for purposes of receiving and tensioning an additional cable from the position shown here in FIG. 10, by rotating screw 72 two or three revolutions in the clockwise direction. This causes tensioner housing 28 to begin moving, albeit slightly, in direction 44, which begins the process of conical clamp jaws 56 being biased in direction 42 within tapered edge 48 creating the clamping force onto cable 10. Once the cable is reinserted, such as that shown in FIG. 6, the tensioning process can resume.

A detail perspective view of a portion of end post 8, with cables 10 extending therein, similar to that shown in FIG. 2, is shown in FIG. 11. Here, in contrast to FIG. 2, a drill 92, with an illustrative Allen wrench bit 94 extending therefrom and fitted within one of the tensioning bolts 14, is shown in this view. With the tensioner housing 28 reset, cable 10 can be inserted into cable hole 16, which will guide it into conical clamp jaws 56 (see FIG. 6). Drill 92 can then rotate Allen wrench bit 94, thereby rotating tensioner bolt 14, which rotates screw 72 in direction 18 to tension cable 10 as described in FIGS. 6-8. Conversely, if that tension cable is intended to be removed, then drill 92 rotates Allen wrench bit 94 in the opposite direction so tensioner bolt 14 rotates in direction 20, which will move tensioner housing 28 back toward wall 76 of end post 8, as shown in FIGS. 9 and 10, to reduce the tension and grip force by conical clamp jaws 56. This allows the cable 10 to be removed from end post 8.

In the drawings, some structural or method features may be shown in specific arrangements and/or orderings. However, it should be appreciated that such specific arrangements and/or orderings may not be required. Rather, in some embodiments, such features may be arranged in a different manner and/or order than shown in the illustrative figures. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all embodiments and, in some embodiments, may not be included or may be combined with other features. It should also be appreciated that, to the extent any subject matter disclosed in this non-provisional patent document conflicts with the priority application, the disclosure from this non-provisional patent document controls.

Claims

1. A cable rail barrier comprising: a top rail that extends between two or more posts;one or more cables that extend between the two or more posts;wherein at least one cable of the one or more cables is configured to couple to at least a first post of the two or more posts;wherein the at least one cable of the one or more cables is configured to be tensioned to provide a desired amount of rigidity;a cable tensioning system that secures and tensions the at least one cable of the one or more cables to the first post, the cable tensioning system includes: a cartridge that includes at least one tensioner housing receptacle;a tensioner housing;wherein the cartridge fits into an interior of the first post;wherein the at least one tensioner housing receptacle includes a first channel and a second channel which are open to each other;wherein between the first channel and the second channel is a first rail component and a second rail component;wherein the first rail component and the second rail component provide a linear path of travel for the tensioner housing which is movable in a first direction and a second direction;wherein the tensioner housing includes a tapered housing component with a conical tapered edge;wherein the tensioner housing includes a threaded housing component with a threaded inner periphery;wherein the tapered housing component of the tensioner housing fits into the first channel of the at least one tensioner housing receptacle and the threaded housing component of the tensioner housing fits into the second channel of the at least one tensioner housing receptacle;wherein a bearing portion is located between the tapered housing component and the threaded housing component of the tensioner housing to allow linear movement of the tensioner housing in either the first direction or the second direction within the at least one tensioner housing receptacle;wherein a passageway is disposed through the tapered housing component of the tensioner housing;a conical clamp jaw fits into the passageway of the tapered housing component;wherein the conical clamp jaw includes a plurality of opposing jaw parts that form a conically shaped body;a spring that exerts a bias force on the conical clamp jaw to bias the conical clamp jaw in the first direction towards the conical tapered edge within the tapered housing component;wherein an end portion of the at least one cable of the one or more cables is extendable through the first post, into the tapered housing component, and fits between the plurality of opposing jaw parts;wherein the spring exerts the bias force on the conical clamp jaw towards the conical tapered edge to provide a grip on the end portion of the at least one cable of the one or more cables;a screw fits into and moves on the threaded inner periphery of the threaded housing component; anda tensioner bolt extends through the first post and secures to the screw;wherein rotation of tensioner bolt rotates the screw, which causes the tensioner housing to move in either the first direction or the second direction;wherein movement of the tensioner housing in the second direction when the at least one cable of the one or more cables is held by the conical clamp jaw pulls the at least one cable of the one or more cables taut and tensions the at least one cable of the one or more cables; andwherein the movement of the tensioner housing in the first direction causes the tensioner housing to move towards an interior wall of the first post to push the conical clamp jaw against the bias force of the spring to allow the at least one cable of the one or more cables to be released from the conical clamp jaw.

2. The cable rail barrier of claim 1, wherein the movement of the tensioner housing in the first direction causes the conical clamp jaw to engage the interior wall of the first post, which moves the conical clamp jaw with respect to the conical tapered edge to relieve the grip on the at least one cable of the one or more cables.

3. The cable rail barrier of claim 1, wherein the movement of the tensioner housing in the second direction causes the conical clamp jaw to engage the conical tapered edge to apply a force against the at least one cable of the one or more cables to further the grip on the at least one cable of the one or more cables.

4. The cable rail barrier of claim 1, wherein the at least one tensioner housing receptacle has an inner periphery that substantially conforms to a shape of an outer periphery of the tensioner housing.

5. The cable rail barrier of claim 1, wherein the screw does not move linearly in either the first direction or the second direction.

6. The cable rail barrier of claim 1, wherein the cable tensioning system further comprises a backing pin attached to the tapered housing component and engages the spring opposite the conical clamp jaw to direct the bias force on the conical clamp jaw towards the conical tapered edge.

7. The cable rail barrier of claim 1, wherein the bearing portion is composed of a material selected from the group consisting of plastic and stainless steel.

8. The cable rail barrier of claim 1, wherein the tensioner housing is composed of a material selected from the group consisting of plastic and stainless steel.

9. The cable rail barrier of claim 1, wherein the cartridge includes one or more positioning tabs located about a periphery of the cartridge to position the cartridge at a predetermined position within the first post.

10. The cable rail barrier of claim 1, wherein a second cartridge is located within the first post.

11. The cable rail barrier of claim 1, wherein a second tensioner housing receptacle of the at least one tensioner housing receptacle is provided on the cartridge.

12. A cable rail barrier comprising: one or more cables that extend between two or more posts;wherein at least one cable of the one or more cables is configured to couple to at least a first post of the two or more posts;wherein the at least one cable of the one or more cables is configured to be tensioned to provide a desired amount of rigidity;a cable tensioning system that secures and tensions the at least one cable of the one or more cables to the first post, the cable tensioning system includes: a cartridge that includes at least one tensioner housing receptacle;a tensioner housing;wherein the cartridge fits into an interior of the first post;wherein the tensioner housing is linearly movable in a first direction and a second direction;wherein the tensioner housing includes a tapered housing component;wherein the tensioner housing includes a threaded housing component;wherein the tapered housing component and the threaded housing component of the tensioner housing fits into the at least one tensioner housing receptacle;wherein a passageway is disposed through the tapered housing component of the tensioner housing;a clamp jaw fits into the passageway of the tapered housing component;a spring that exerts a bias force on the clamp jaw to bias the clamp jaw in the first direction within the tapered housing component;wherein an end portion of the at least one cable of the one or more cables is extendable through the first post, into the tapered housing component;wherein the spring exerts the bias force on the clamp jaw to provide a grip on the end portion of the at least one cable of the one or more cables;a screw that fits into and rotates within the threaded housing component, which causes the tensioner housing to move in either the first direction or the second direction;wherein movement of the tensioner housing in the second direction when the at least one cable of the one or more cables is held by the clamp jaw pulls the at least one cable of the one or more cables taut and tensions the at least one cable of the one or more cables; andwherein the movement of the tensioner housing in the first direction causes the tensioner housing to move against the bias force of the spring to allow the at least one cable of the one or more cables to be released from the clamp jaw.

13. The cable rail barrier of claim 12, wherein the movement of the tensioner housing in the first direction causes the tensioner housing to move towards an interior wall of the first post to push the clamp jaw against the bias force of the spring to allow the at least one cable of the one or more cables to be released from the clamp jaw.

14. The cable rail barrier of claim 12, wherein the cable tensioning system further comprises a tensioner bolt that extends through the first post and secures to the screw, wherein rotation of tensioner bolt rotates the screw, which causes the tensioner housing to move in either the first direction or the second direction.

15. The cable rail barrier of claim 12, wherein the screw fits into and rotates within a threaded inner periphery of the threaded housing component.

16. The cable rail barrier of claim 12, wherein the tapered housing component includes a tapered edge, wherein the spring exerts the bias force on the clamp jaw towards the tapered edge to provide the grip on the end portion of the at least one cable of the one or more cables.

17. The cable rail barrier of claim 12, wherein the clamp jaw is a conical clamp jaw that includes a plurality of opposing jaw parts that form a conically shaped body, and wherein the end portion of the at least one cable of the one or more cables is extendable through the first post, into the tapered housing component, and fits between the plurality of opposing jaw parts.

18. The cable rail barrier of claim 12, wherein the at least one tensioner housing receptacle includes a first channel and a second channel which are open to each other, wherein between the first channel and the second channel is a first rail component and a second rail component, and wherein the first rail component and the second rail component provide a linear path of travel for the tensioner housing in the first direction and the second direction.

19. The cable rail barrier of claim 18, wherein the tapered housing component of the tensioner housing fits into the first channel of the at least one tensioner housing receptacle and the threaded housing component of the tensioner housing fits into the second channel of the at least one tensioner housing receptacle, and wherein a bearing portion is located between the tapered housing component and the threaded housing component of the tensioner housing to allow linear movement of the tensioner housing in either the first direction or the second direction within the at least one tensioner housing receptacle.

20. A cable rail barrier comprising: one or more cables that extend between two or more posts;wherein at least one cable of the one or more cables is configured to couple to at least a first post of the two or more posts;wherein the at least one cable of the one or more cables is configured to be tensioned to provide a desired amount of rigidity;a cable tensioning system that secures and tensions the at least one cable of the one or more cables to the first post, the cable tensioning system includes: a tensioner housing;wherein the tensioner housing is linearly movable in a first direction and a second direction;wherein the tensioner housing includes a tapered housing component;wherein the tensioner housing includes a threaded housing component;wherein a passageway is disposed through the tapered housing component of the tensioner housing;a clamp jaw fits into the passageway of the tapered housing component;a spring that exerts a bias force on the clamp jaw to bias the clamp jaw in the first direction within the tapered housing component;wherein an end portion of the at least one cable of the one or more cables is extendable into the tapered housing component;wherein the spring exerts the bias force on the clamp jaw to provide a grip on the end portion of the at least one cable of the one or more cables;a screw that fits into and rotates within the threaded housing component, which causes the tensioner housing to move in either the first direction or the second direction;wherein movement of the tensioner housing in the second direction when the at least one cable of the one or more cables is held by the clamp jaw pulls the at least one cable of the one or more cables taut and tensions the at least one cable of the one or more cables; andwherein the movement of the tensioner housing in the first direction causes the tensioner housing to move against the bias force of the spring to allow the at least one cable of the one or more cables to be released from the clamp jaw.