This invention relates generally a connector for use in railing systems, and more particularly to a connector for mounting a picket to a rail.
Railing systems may generally include an opposed a bottom rail, and top rail and pickets mounted vertically therebetween. The top and bottom rails may include horizontally extending sections and angled sections, such as for steps or inclined ground. Typically, apertures must be cut into the opposing surfaces of the bottom rail and top rail so as to receive ends of the pickets. The installer must estimate the size of the aperture to be cut into the rails, which may be not only be time consuming and inefficient, but also difficult if the pickets will be installed at an angle to the rail. Also, because of cutting tolerances, the pickets may not be tightly received in the railing and resulting in a less durable, weaker railing system than if there were a tight fit. Further, the pickets have portions extending into the rails and thus, are longer than what is actually needed, resulting in added shipping costs and material costs.
For the foregoing reasons, there is a need for an apparatus that will allow for efficient assembly of horizontal and angled sections of railing systems. There is a further need for the apparatus to enhance the strength and durability of such structures while reducing shipping and material costs.
According to the present invention, a connector is provided for securing together a first member and a second member, where each of the first and second members has an aperture and a wall thickness at the point of joining. The connector includes a body portion having a generally circular cross-section taken along a plane that is perpendicular to a longitudinal axis of the body portion. Further, the connector is secured to the first member in the aperture by an attachment being rigidly joined to the body portion.
Also, in accordance with the present invention, a connector is provided for securing together a first member and a second member, each of the first and second members having an aperture and a wall thickness at the point of joining. The connector has a first body portion, a second body portion and a flange. The first body portion has a grommet for being received within the aperture of the first member, an ear protrusion extending radially from the grommet, and at least one resilient arm connected to the grommet. The resilient arm allows for securing the first body portion to the first member and the ear protrusion allows prevents rotation of the connector by mating with a notch formed in the aperture of the first member. The second body portion of the connector has a generally circular cross-section taken along a plane that is perpendicular to a longitudinal axis of the body portion. The flange forms a transverse interior end of the second body portion and an interior end of the first body portion is rigidly joined to the flange. The flange includes an internal diameter surface flush with an internal diameter surface of the first body portion and has an external diameter surface flush with at least a portion of an external diameter surface of the second body portion. The external diameter of the flange is greater than a diameter of the grommet. Additionally, the resilient arms are formed in and extend from a sidewall of the first body portion toward an outer face of the flange and the arms have a free end including a retaining end surface adapted for having close proximity to a first side of and surrounding the aperture of the first member. The free end of the first arm is tapered outwardly from the sidewall and is resiliently inwardly movable by camming contact with the periphery of the aperture in the first member as the at least one resilient arm passes through the aperture in the first member. Accordingly, when the retaining end surface moves free of the aperture, the resilient arms move outwardly to a position where a bottom portion of its retaining end surface opposes and engages a portion of an inside face of the first member extending inward from an edge portion of the associated aperture. This allows for captively retaining the entire wall thickness of the aperture of said first member between the internal diameter surface of the flange and the retaining end surface of the first arm.
Further in accordance with the present invention, a railing system has at least one rail, at least one picket, and a connector. The connector secures together the rail and the picket. The rail has an internal cavity and a sidewall that defines an aperture and the picket has at least one open end and abuts the rail at the aperture. The connector has a body portion having a generally circular cross-section taken along a plane that is perpendicular to a longitudinal axis of the body portion. Further, the body portion is dimensioned so as to fit within the open end of the picket an attachment is employed to secure the connector to the rail in the aperture. The attachment is rigidly joined to the body portion and is dimensioned so as to fit within the internal cavity of the rail.
Yet further in accordance with the present invention, a method for assembling a railing system may be accomplished by providing a rail including a wall defining an aperture, a picket comprising an open end, and providing a connector for securing together the rail and the picket at the rail aperture. The method further comprises the steps of securing the connector to the rail and securing the picket to the connector. The connector employed includes a body portion and an attachment. The body portion of the connector has a generally circular cross-section taken along a plane that is perpendicular to a longitudinal axis of the body portion. The attachment secures the connector to the rail and is rigidly joined to the body portion.
These and other objects, features and advantages of the present invention will be apparent from the following description thereof and appended claims in which references are made to the accompanying drawings.
For a more complete understanding of the present invention, reference should now be had to the embodiments shown in the accompanying drawings and described below. In the drawings:
Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” “transverse”, “longitudinal” and “downward” merely describe the configuration shown in the FIGs. Indeed, the individual components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise.
Referring now to the drawings, wherein like reference numbers refer to like elements in each of the several views,
Referring to
The grommet 34 of the first portion 30 has a body having a generally cylindrical shape. The grommet body is substantially elongated along an axis that is perpendicular to the longitudinal plane where the first and second portions intersect. The grommet 34 has a proximate end located at the intersection of the first 31 and second portions 32, and a distal end located opposite of the proximate end and farthest from the second portion 32. The grommet 34 also has a diameter that is generally smaller than the diameter of the second portion 32 of the connector 28.
The pair of opposed resilient arms 36 extends from the grommet 34 and may be formed from at least a portion of the body of the grommet 34. The illustrative embodiments of
The ears 38 of the first portion 30 are protrusions outwardly extending from the proximate end of the grommet 34 along the longitudinal plane defined by the intersection of the first 31 and second portions 32. One or more ears 38 may protrude from any side of the grommet 34.
The second portion 32 generally includes a body 48 that may have, in one embodiment, a generally cylindrical shape. The cylindrical shape yields a circular cross-section taken along a plane that is perpendicular to a central longitudinal axis of the second portion 32. Although the illustrated embodiments are described herein with the second portion 32 having a cylindrical body 48, it should be understood that the second portion 32 may have any shape, including spherical, square, triangular, pyramidal, polygonal, any combination thereof and the like. In another embodiment, the second portion 32 may have a shape so that when the second portion 32 is received in an interior cavity of the picket, the body 48 of the second portion 32 makes contact with at least a portion of the interior surface of two pairs of opposing interior surfaces (or contact along the circumference in the case of a round picket) of the interior cavity of the picket. As such, for example, the second portion 32 may have a shape having at least two curved portions and two flat sides 50. Additionally, the second portion 32 may be a truncated sphere, a truncated cylinder, a chamfered cylinder, a crescent shape, a combination thereof, and the like. As seen in
The cylindrical body 48 also includes two opposing sides, both of which have outer surfaces that have at least a portion 50 that is flat. The flat portion 50 of each opposing side is aligned along a plane which is oriented perpendicular to a longitudinal axis. In the illustrative embodiments, two flat sides 50 are shown, but it will be appreciated that any number of flat sides 50 may be utilized.
In one embodiment, the cylindrical body 48 may have multiple finger-like sections 52. The finger-like sections 52 define cut-out portions or slots 54 in the cylindrical body 48, as shown in
The cylindrical body 48 may also comprise a flange 44. The flange 44 radially extends along the base of the second portion 32. The transverse dimension of the flange 44 is greater than the transverse dimension of the proximate end of the grommet 34. The flange 44 may be integral with the cylindrical body 48. However, the shape of the flange 44 may be radially flat so as to be able to flushly abut the rail 25 when connected to the rail 25.
In use, the connectors 28 secure the pickets 22 to the rails 25, as shown in
The connector 28 may be first inserted into the aperture 42 of the rail 25. To accomplish this, the first portion 30 is inserted into the rail 25 guided by the grommet 34 and the ear insertion guides 46. When inserting the first portion 30 into the rail aperture 42, the free ends 40 of the arms 36 are forced to bend inward toward the grommet 34 by the sidewall 58, generating a camming action to be placed from an “unloaded” position into a “loaded” position. Once the free ends 40 of the arms 36 have passed beneath the periphery of the aperture 42, they spring back outwardly into the “unloaded” position, and thereby underlay the periphery of the aperture 42 along the adjacent inside surface of the sidewall 58 of the rail 25, thereby preventing the first portion 30 from being withdrawn from the aperture 42. More specifically, the sidewall 58 of the rail 25 is captively retained between the flange 44 (shown best in
Once installing the connector 28 in the rail 25, the first portion 30 resides in the inner cavity 62 of the rail 25 while the second portion 32 protrudes out from the rail 25. At this point, the picket 22 may be connected to the rail 25 by attachment to the second portion 32 of the connector 28 by mechanical means and with adhesive (not shown). Each picket 22 has an interior cavity 60 and at least one open end, which is sized to receive and retain the second portion 32 of the connector 28. As the open end of the picket 22 is moved toward the rail 25, the inner periphery 66 of the picket's interior cavity 60 fits around the second portion 32 such that at least a portion of the surface of the cylindrical body 48 contacts the surface of the interior cavity periphery 66. In a preferred embodiment, both flat side portions 50 make contact with the interior cavity periphery 66 and, in addition, two other opposing portions of the second portion make contact with two opposing surfaces of the interior cavity periphery 66 so that the second portion 32 makes contact substantially around the entire interior cavity periphery 66. This position is shown in
To complete the installation of the picket 22 to the rail 25, the end of the picket 22 is advanced toward the rail 25 until the end of the picket 22 abuts against the outer surface of the rail 25. This position is illustrated in
In one embodiment, the picket 22 may be attached to the rail 25 at an angle θ such that the picket 22 is not perpendicular to the rail 25, as can be seen in
The procedure as described above is performed for each end of the picket 22. One end of the picket 22 may be connected to the base rail 26 and the other end may be connected to the handrail 24. After installation, the connectors 28 are hidden within the railing system 20.
Although the above procedure describes attaching the first portion 30 of the connector 28 to the rail 25 prior to attaching the picket 22 to the second portion 32 of the connector 28, any order of attaching the connector 28 to the rail 25 and picket 22 may be performed. For example, the second portion 32 may first be connected to the picket 22 prior to attaching the first portion 30 to the rail 25. Additionally, although the description above is an example of use of the connectors 28 for connecting pickets 22 to rails 25, the connectors 28 are also applicable for use in joining the rails 25 to other supporting structures, such as posts or walls, and for use in numerous other configurations for joining individual members together.
In one embodiment, prior to inserting the second portion 32 into the picket 22, an adhesive (not shown) is placed on the cylindrical body 48 of the connector 28 so as to adhere the second portion 32 securely to the interior cavity periphery 66. The adhesive adheres the second portion 32 of the connector 28 to the picket 22 and optionally, the rail 25. If the cylindrical body 48 has cut-out portions 54, the adhesive may be accommodated therein so as to provide a greater surface area of the connector 28 for bonding to the picket 22 via the adhesive.
The cylindrical body 48 of the second portion 32 allows the pickets 22 to be secured at any angle θ to the rail 25 in the case of stairway railing (
The present invention allows the picket 22 length to extend from the top surface of the bottom rail 26 to the underside surface of the hand rail 24. Accordingly, as compared to conventional pickets 22, which have a longer length, the amount of material that must be used in fabricating each picket 22 is less than and as such, may reduce any associated costs.
The present invention may also provide a more secure and stable connection of the picket 22 to the rail 25 than previous systems due to the cylindrical body 48 snugly fitting in the interior cavity 60 of the picket 22, regardless of whether the picket 22 is angled with respect to the rail 25.
The connectors 28 of the present invention allow the pickets 22 and railings 24, 26 to be shipped separately, and can be easily snapped together in the field. This may result in less shipping costs as the shipped parts may be lighter and more compact. The connectors 28 facilitate assembly of the picket 22 to the rail 25 since the picket 22 only has to be aligned with the connector 28 once the connector is affixed to the rail. Further, the connector 28 can be used universally for either horizontal or sloped railings.
Although the present invention has been shown and described in considerable detail with respect to only a few/particular exemplary embodiments thereof, it should be understood by those skilled in the art that it is not intended to limit the invention to the embodiments since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages of the invention, particularly in light of the foregoing teachings. Accordingly, the present invention is intended to cover all modifications, omission, additions and equivalents as may be included within the spirit and scope of the invention as defined by the following claims.