The present invention relates generally to barriers (such as railings or fences) and in particular to a railing panel with horizontal or angled slats that has an adjustable length.
It is common to form a barrier for railing or fence applications made, for example, of a plurality of panel members, with each panel member supported between and attached to a pair of post members. Each panel generally comprises a bottom rail extending between two posts and a top rail also extending between those same two posts. A plurality of vertical support members (also referred to in the art as pickets or balusters) extend between the bottom rail and the top rail. The bottom rail, top rail and vertical support members are made of a metal material (such as steel or aluminum). In an embodiment, first ends of the vertical support members are fixedly attached to the bottom rail (for example, through brackets or welding) and second ends of the vertical support members are fixedly attached to the top rail (again, for example, through brackets or welding).
The panel may be pre-assembled before delivery to a job site. In such a case, the installer may simply install the pair of posts with a separation substantially equal to a length of the panel. The installed posts may have an exposed height that is greater than a height of the panel. Brackets mounted on each post accept and retain ends of the bottom and top rails. However, situations arise where the distance between the posts is shorter than a length of a panel. In this instance, the panel may be cut to a length that fits between the posts, which would leave top and bottom rail portions extending beyond a baluster at each end. The top and bottom rails may be secured to the posts resulting in a satisfactory railing assembly.
If the balusters extend horizontally, as opposed to vertically, cutting to fit between posts that are spaced apart a distance that is shorter than the manufactured length of the rail panel presents additional challenges.
In an embodiment, a railing panel includes a top rail and a bottom rail disposed spaced apart from the top rail. A plurality of slats are disposed between and run parallel to the top rail and the bottom rail. A midspan support rail defines a plurality of through holes, with each through hole receiving a slat therethrough. A length adapter includes an upright end rail that defines a plurality of apertures, and an upper insertable portion that is disposed at a first end of the upright end rail. The length adapter also includes a lower insertable portion that is disposed at a second end of the upright end rail opposite the first end, and each of the plurality of apertures is sized and shaped to receive an end of each of the plurality of slats. A plurality of inserts are coupled to the upright end rail, with each insert disposed proximate a respective aperture of the plurality of apertures, each insert configured to be received by a respective slat.
According to one embodiment, the railing panel may be a level railing panel with top and bottom rails and slats running horizontally. The inserts may be biased to exert a force on an internal surface of a wall of the slats. The biased inserts may inhibit rattling of the slats.
According to an alternate embodiment, the railing panel may be an inclined railing panel with top and bottom rails and slats running at a nonperpendicular rake/rack angle. The inserts may be pivotable to accommodate the slats running a range of rake angles. A pivot pin may be received through the mid span support and a slat to allow the slat to pivot to position the inclined railing panel and a nonperpendicular angle to follow stairs or a sloped terrain.
Advantages of the disclosed embodiments of the length adjustable railing panels with removable upright end rails include a railing panel that can be easily cut to fit a shorter post spacing than common six or eight foot post spacing. The railing panel can be easily cut down and reassembled without requiring welding or customization for the railing panel to fit a particular post spacing. The advantages extend to level railing and inclined railing with the reassembled panel being adjustable through a range of rake angles.
A more complete understanding of the method and apparatus of the present invention may be acquired by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein:
Reference is now made to
The railing panel 10 includes a pair of length adapters 20 disposed proximate each end of the railing panel 10. According to certain embodiments, the railing panel 10 may also include a mid-span support rail 24. The infill of the railing panel 10 includes a plurality of spaced apart slats 26. Each of the slats 26 extends longitudinally from an upright end rail 22 of a length adapter 20 at one end to an upright end rail 22 of a length adapter 20 at the opposite end.
The mid-span support rail 24 includes a plurality of through holes 25 through which each slat 26 extends (see
The slats may be a generally hollow structure formed with sheet metal. According to one embodiment, the slats may have a dimension in a range of 0.25-1.0 inches square, for example 0.6 inches square. The edges of the slats may be rounded. The sheet metal may have a thickness in a range of approximately 0.02-0.06 inches, for example 0.040 inches. The slats 26 may be formed from aluminum or other material that may be extruded or otherwise fabricated to form an elongated bar with a square-shaped cross-section. According to one embodiment, the slats 26 are roll formed and provided with a seam that runs the length of the slat 26. According to an embodiment, the slats 26 are fabricated from galvanized steel. According to an alternate embodiment, the slats 26 may be formed by extruding aluminum.
Reference is now made to
According to embodiments of the present disclosure, the open space between the support post and the upright end rail 22 of the length adapter 20 is maintained on each end of the railing panel 10. This spacing may be in a range of 2-8 inches, for example approximately four inches.
The length adapters 20 may be provided as part of the assembled rail panel 10, as shown in
The length adapters 20 are shown exploded from the cut down railing panel 10. Each length adapter 20 is configured to be secured to the cut down railing panel 10 and to be secured to one of the support posts. The length adapters 20 accommodate a cut length of the railing panel 10 and maintain the spacing between the posts 12, 14 and the upright end rails 22 of the length adapter 20.
Reference is made to
The upright end rail 22 may be punched to form a plurality of apertures 38 through a front face 40. The apertures 38 are sized and shaped to receive an end portion of a slat 26 therein.
The top rail adapter 34 includes an insertable portion 42 and a top rail extender 44. The insertable portion may be a U-shaped member formed of any suitable material, such as aluminum or steel. The top rail extender 44 has a square shaped cross-section sized to correspond to the size and shape of the top rail 16. The insertable portion 42 and the top rail extender 44 may each be sized to allow the insertable portion 42 to be received by the top rail extender 44 and secured therein using any suitable joining technique, such as welding. Upon being inserted into the top rail extender 44, the insertable portion 42 extends a predetermined distance beyond the top rail extender 44, as shown in
The bottom rail adapter 36 includes an insertable portion 46 and a bottom rail extender 48. The insertable portion 46 may be a U-shaped member formed of any suitable material, such as aluminum or steel. The bottom rail extender 48 has a square shaped cross-section sized to correspond to the size and shape of the bottom rail 18. The insertable portion 46 and the bottom rail extender 48 may each be sized to allow the insertable portion 46 to be received by the bottom rail extender 48 and secured therein using any suitable joining technique, such as welding. Upon being inserted into the bottom rail extender 48, the insertable portion 46 extends a predetermined distance beyond the bottom rail extender 48, as shown in
A cover 50 may include a generally flat bar 52 that is welded or otherwise secured to the open face of the upright end rail 22. A plurality of biased inserts 54, which may also be referred to as clips, are welded or otherwise secured to be disposed equally spaced apart along the length of the cover 50. When the cover 50 is welded to the upright end rail 22, the biased inserts 54 align with a respective aperture 38 in the upright end rail 22.
As discussed above, the assembled and welded length adapter 20 may be provided separately from the rail panel 10 to allow the installer to use when the spacing between posts does not fit the length of the manufactured and preassembled rail panel 10.
The length adapter 20 is assembled to an end of the cut down rail panel 10. The insertable portion 46 is inserted into an end of the bottom rail 18, and the insertable portion 42 is inserted into and end of the top rail 16. Alternatively, the top rail 16 may be inserted into the insertable portion 42, and the bottom rail 18 may be inserted into the insertable portion 46. According to an embodiment, a fastener may be received through a wall of the top rail 16 and into a wall of the insertable portion 42, preferably the bottom walls to obscure view of the fastener. However, the insertable portion 42 may simply be inserted into and friction fit into the top rail 16. Similarly, the insertable portion 46 may be inserted and friction fit into an end of the bottom rail 18, and may optionally be secured with a fastener.
The top and bottom rails 16, 18 and the top and bottom rail extenders 44, 48 may be generally hollow structures with a square cross section and may be formed of any suitable material, such as aluminum or steel. According to one embodiment, the top and bottom rails 16, 18 and the top and bottom rail extenders 44, 48 are formed of sheet metal, for example galvanized steel. According to an alternate embodiment, they may be formed of extruded aluminum. According to one embodiment, top and bottom rails 16, 18 and the top and bottom rail extenders 44, 48 may have a dimension in a range of 0.5-1.5 inches square, for example 1.0 inches square. The edges of top and bottom rails 16, 18 and the top and bottom rail extenders 44, 48 may be rounded. The sheet metal may have a thickness in a range of approximately 0.04-0.10 inches, for example 0.060 inches. According to one embodiment, top and bottom rails 16, 18 and the top and bottom rail extenders 44, 48 are roll formed into a member with a square cross section with a welded seam that runs their respective length. Alternatively, top and bottom rails 16, 18 and the top and bottom rail extenders 44, 48 may have a U-shaped cross section.
According to an embodiment, the flat bar 52 of the cover 50 may be a sheet of galvanized steel with a thickness in a range of in a range of approximately 0.04-0.10 inches, for example 0.060 inches.
A second length adapter 20 is similarly assembled to the opposite side of the cut-down rail panel 10. The rail panel 10 assembled with a length adapter 20 on each side is coupled to the support posts, similarly to as shown in
Additional fasteners may be unnecessary in assembling the rail panel 10 to the length adapters 20 because positioning the railing panel 10 assembled with the length adapters 20 between and supported by two posts 12, 14 adequately holds the assembly together. Thus, the length of the railing panel 10 may be cut down to any suitable length and fitted with the length adapters 20 to allow customization of a preassembled railing panel without welding or other joining techniques.
Reference is made to
An upper support post 62 supports an upper end of the incline railing panel 60, and a lower support post 64 supports a lower end of the incline railing panel 60. According to an embodiment, a pair of pivotable brackets 65 is secured to a face of the upper support post 62, and a second pair of pivotable brackets 65 is secured to the lower support post 64. The brackets 65 hold the incline length adapters 70, similarly to as described above with respect to
According to an embodiment the incline railing panel 60 is assembled to allow it to pivot through a range of rake (or rack) angles. For example, the pivotable connections of the components of the incline railing panel 60, as described in more detail below, facilitate a rake angle in a range of zero to 45° with respect to horizontal. According to one embodiment, the railing panel is adjustable in a range of 20° thru 50° with respect to horizontal, for example a 30°-40° range with respect to horizontal is shown in the illustrated embodiment. A plurality of slats 76 creates the infill of the incline railing panel 60. The slats 76 are pivotably coupled to a mid-span support rail 74. More specifically, a plurality of through holes 75 are formed through the mid-span support rail 74 and are sized and shaped to receive a respective slat 76 and to allow clearance for the slat 76 to pivot through the rake angle. A pivot pin is received through the mid-span support rail 74 and through a corresponding through hole in the slat 76. The pivot pin may be welded or otherwise secured to the mid-span support rail 74. Each slat 76 is pivotable about its respective pivot pin.
As discussed above with respect to
Reference is made to
The upright end rail 72 may be formed of any suitable material, such as aluminum or steel, and may have any suitable cross-sectional shape, for example square. A plurality of equally spaced apart apertures 88 are formed in a front face 90 of the upright end rail 72. The apertures are sized and shaped to receive an end of a respective slat 76 and provide clearance for the slat 76 to pivot through the rake angle. In one embodiment, the apertures 88 are rectangular and have a long dimension to short dimension ration of approximately 1.5 to 1. For example, the apertures 88 may have a short dimension of approximately 0.6 inches and a long dimension of approximately 0.9 inches.
The top rail adapter 84 includes an insertable portion 92 and a top rail extender 94. The insertable portion may be a U-shaped member formed of any suitable material, such as aluminum or steel. The top rail extender 86 has a square shaped cross-section sized to correspond to the size and shape of the top rail 66. The insertable portion 92 and the top rail extender 94 may each be sized to allow the insertable portion 92 to be received by the top rail extender 94 and secured therein using any suitable joining technique, such as welding. Upon being inserted into the top rail extender 94, the insertable portion 92 extends a predetermined distance beyond the top rail extender 94, as shown in
According to an embodiment, a bottom face of the top rail extender 94 may be welded to an upper hinge block 93. The upper hinge block 93 may be received and pivotably attached to the upright end rail 72 using a pivot pin. According to an embodiment, the upper end of the upright end rail 72 may include an angled upper end 95. The non-perpendicular angle of the upper end corresponds to a rake angle of the incline railing panel 60 and also provides clearance for the top rail adapter 84 to pivot through the rake angle.
The bottom rail adapter 86 includes an insertable portion 96 and a bottom rail extender 98. The insertable portion 96 may be a U-shaped member formed of any suitable material, such as aluminum or steel. The bottom rail extender 98 has a square shaped cross-section sized to correspond to the size and shape of the bottom rail 68. The insertable portion 96 and the bottom rail extender 98 may each be sized to allow the insertable portion 96 to be received by the bottom rail extender 98 and secured therein using any suitable joining technique, such as welding. Upon being inserted into the bottom rail extender 98, the insertable portion 96 extends a predetermined distance beyond the bottom rail extender 98, as shown in
According to an embodiment, a bottom face of the bottom rail extender 98 may be welded to a lower hinge block 97. The lower hinge block 97 may be received and pivotably attached to the upright end rail 72 using a pivot pin. According to an embodiment, the lower end of the upright end rail 72 may include an angled lower end 99. The non-perpendicular angle of the angled lower end 99 corresponds to a rake angle of the incline railing panel 60 and also provides clearance for the bottom rail adapter 86 to pivot through the rake angle.
A pivotable insert 100 is received in each of the apertures 88 and pivotably coupled to the upright end rail 72 with a hinge pin 102 that is receive through holes 104 in the side walls 106 of the upright end rail 72.
Reference is made to
A rear surface 118 of the base 108 is rounded to provide clearance from a rear wall 113 of the upright end member 72 to allow the pivotable insert 100 to pivot through the rake angle.
The projection portion 110 of the pivotable is sized and shaped to be received by an end of a slat 76. The projection may be tapered to facilitate insertion into the slat 76. The insert may be friction fit into the slat 76. Additional fasteners may be omitted due to the friction fit of the projection in the slat 76.
Similar to the discussion with respect to
Although preferred embodiments of the method and apparatus 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.
This application is related to U.S. Pat. No. 9,976,320, entitled “Horizontal Cable Rail Barrier,” filed on Apr. 13, 2015, which claims priority to U.S. Provisional Application for Patent No. 61/979,083, filed on Apr. 14, 2014, the disclosures of each of which are incorporated herein by reference.