1. Technical Field
This invention generally relates to fencing systems. More particularly, the invention relates to a method and apparatus for attaching spindles to a rail assembly. Specifically, the invention relates to a spindle racking assembly that includes a first member that engages the rail and a second member that engages the spindle and is pivotally mounted to the first member and movable relative thereto to set the angle of the spindle relative to the rail.
2. Background Information
One of the problems encountered when building a vinyl fence assembly is that of being able to quickly and easily connect spindles between spaced apart rails. Because of the type of material involved, the installer cannot simply place the spindle on the rail and drive a toe nail into the same. One of the easiest solutions is for the rail to be made with a plurality of apertures cut at predefined intervals. One end of each spindle in inserted into the lower rail and the other end thereof is inserted into the lower rail. While the method sounds easy, any differences between the size of the apertures and the ends of the spindle can be problematic. Firstly, if the aperture is too small or is slightly incorrectly cut, the end of the spindle will not be able to be inserted into the same. On the other hand, if the aperture is too big then the spindle will be easily inserted but will tend to move around in the aperture making the installation of the upper rail difficult. Additionally, there will tend to be a gap around the end of the spindle and the rail thus giving the finished product an unfinished and unpolished appearance.
The problem is especially pronounced in the construction of stair rail assemblies. In this instance, two inclined rails have to be installed in such a manner that the apertures therein are aligned in exactly the correct orientation relative to each other. If there is a misalignment of the same, then the spindle may be able to be inserted into the aperture in the lower rail but be angled to the point that it cannot be received in the upper rail. Even if the spindles can be installed, they may not be angled correctly relative to the rails. If the angle is even slightly off, then the stair rail assembly will have a misaligned appearance that can make the entire assembly look as if it has been installed by an amateur.
There is therefore a need in the art for a reliable and easily used method and apparatus for installing spindles between a pair of rails.
The device of the present invention is a racking assembly for adjustably mounting a spindle to a rail. The racking assembly includes a first member which engages the rail and a second member pivotally secured to the first member. The second member retains the spindle at an angle relative to the first member and therefore relative to the rail. As the second member pivots, the angle of the spindle relative to the rail is changed. The racking assembly gives an installer the ability to correctly set the angles of the spindles in a stair rail assembly that is to be used on stairs that range in steepness from between 25 and 40 degrees and preferably between 28 and 38 degrees.
In a fence rail assembly or stair rail assembly, each spindle is secured between an upper and lower rail by a pair of racking assemblies. Each racking assembly is mounted on one of the upper and lower rails and is individually adjustable so as to set the angle of the spindle relative to the rails. The rails are secured between a pair of vertical posts. Each rail is secured to one of the posts by a bracket that is adjustable to set the angle of the rail relative to the posts
The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
Referring to
In accordance with a specific feature of the present invention, each of the racking assemblies 12 is configured to be engaged in one of apertures 26 in one of the hand and foot rails 18, 20. Furthermore, each spindle 22 is secured between a pair of racking assemblies 12. A single racking assembly 12 is shown in greater detail in
Referring still to
Rail pivot 28 further includes a perimeter wall 34 that extends downwardly away from lower surface 32c. Preferably, perimeter wall 34 comprises two substantially C-shaped regions 34a, 34b, each of which extends along one full side 32a or 32b of base 32 and partially along each of the two adjacent sides 32d, 32e thereof. Regions 34a, 34b are opposed to each other and are spaced a distance apart that is substantially equal to the length S of aperture 26. Consequently, when rail pivot 28 is engaged in aperture 26, wall regions 34a, 34b extend downwardly through aperture 26 and into the interior of rail 20. Rail pivot 28 preferably further includes a pair of opposed flanges 36 that extend downwardly from lower surface 32c and intermediate wall regions 34a, 34b. Each flange 36 includes a shoulder 36a that faces outwardly and is separated from lower surface 32c of base 32 by a notch 35 (
In accordance with yet another feature of the present invention, rail pivot 28 further includes an exterior wall comprising an arcuate wall 44 and two opposed sides 50. Arcuate wall 44 is substantially semicircular in shape and extends upwardly and outwardly away from base 32. Arcuate wall 44 originates proximate a first side 32a of base 32 and terminates proximate a second side 32b thereof. Arcuate wall 44 describes an arc of substantially 180 degrees about an axis X. Axis X is disposed at right angles to the longitudinal axis Y of base 32. Sides 50 extend upwardly from proximate sides 32d, 32e of base 32 and join arcuate wall 44 along a first and second semicircular edge 45. A portion of arcuate wall 44 extends outwardly beyond edges 45 thereby forming a pair of opposed lips 46 that project beyond sides 50 and over sides 32d, 32e of base. Each lip 46 has a first end 47 and a second end 49. As shown in
Exterior wall 42 is marked with an indicator arrow 48 to indicate a direction of rotational engagement for spindle cover 30 as will be hereinafter described. Arrow 48 has an end 48a and a tip 48b. It will be understood that arrow 48 may be a marking placed on arcuate wall 44 or may be a recessed or raised region formed on arcuate wall 44 or anywhere else on exterior wall 42.
Spindle cover 30 is designed to interlockingly engage rail pivot 28 and to be movable relative thereto. Referring to
In accordance with yet another feature of the present invention and as shown in
The racking assembly 12 of the present invention is used in the following manner. The installer first mounts a lower bracket base 70 (
A spindle cover 30 is then engaged with each rail pivot 28. This is accomplished by positioning cover 30 over rail pivot 28 so that edge 52b of side wall 53c is in close proximity to region 32b on base 32 and arcuate portion 62 of bottom wall 54 rests of wall 44 of rail pivot 28. Spindle cover 30 is then rotated about the axis X and in the direction indicated by arrow 48 so that end 47 of lip 46 enters groove 66 in wall 54. Spindle cover 30 continues to be rotated in the direction indicated by the arrow until lip 46 is substantially entirely received in groove 66. At this stage, spindle cover 30 cannot be disengaged from rail pivot 28 by pulling upwardly or side to side. Spindle cover 30 can only be released from rail pivot 28 by rotating it in the opposite direction to that indicated by the arrow and to the degree that lip 46 becomes completely disengaged from groove 66. The position of lips 46 on edge 45 is such that spindle cover 30 can be rotated about axis X and through at least 90 degrees and not become disengaged from rail pivot 28. It will be understood that spindle cover 30 could be engaged with rail pivot 28 before rail pivot 28 is inserted into aperture 26, but cover 30 tends to obscure the base 32 and it is therefore more desirable to insert rail pivot 28 into aperture 26 prior to engaging spindle cover 30 with rail pivot 28.
The installer secures upper rail bracket assemblies 24 into position on posts 14, 16. Hand rail 18 is lowered into brackets of upper rail bases 70 and the installer begins installation of racking assemblies 12 onto hand rail 18 by snap-fitting a rail pivot 28 into each aperture 26 in hand rail 18. Once again, care must be taken to ensure that arrows 48 on all of rail pivots 28 on hand rail 18 point in the same direction. The rail pivots 28 in fence rail assembly 10 preferably are oriented so that the tips 48b of the arrows 48 face upwardly toward the uppermost post 16 on the stairway. In other words, the arrows 48 on rail pivots 28 on foot rail 20 point in a first direction and the arrows 48 on the rail pivots 28 on hand rail 18 point in a second and opposite direction. Hand rail 18 is placed into position at this time so that the installer can check that the arrows on the rail pivots in the hand rail 18 are opposite in orientation to those of the pivots in the foot rail 20. A spindle cover 30 is then engaged with each rail pivot 28 in hand rail 18 in the same manner as was described with reference to the foot rail 20. When the installer is sure that all racking assemblies 12 are installed in the correct orientations, the hand rail 18 is removed.
The installer then engages spindles 22 in racking assemblies 12. A spindle 22 is inserted into each spindle cover 30 of racking assemblies 12 in foot rail 20. This is accomplished by pushing spindle 22 downwardly so that side walls 62 thereof slide into gap 58 between outer wall 52 and supports 56. Spindle 22 is pushed downwardly until the lowermost edge of spindle 22 contacts the interior surface of bottom wall 54 (
In accordance with another of the features of the present invention, spindle cover 30, and therefore spindle 22 retained therein, can be slidably moved along wall 44 of rail pivot 28. This enables the installer to set the tilt or angle of the spindles 22 relative to wall 20a. So, for example, spindles 22 can be positioned at any angle between 25 and 40 degrees relative to wall 20a of rail 20. The ability to vary the tilt of the spindles 22 is important for installing fence rail assemblies on stairways that are of different steepness. On a very steep stairway it is necessary to set the spindles 22 at a more acute angle relative to rail 20, e.g., an angle of 25 degrees. On a less steep stairway, the spindles 22 can be set at a less acute angle, e.g., 35 degrees relative to rail 20.
Once all spindles 22 are installed in racking assemblies 12 in foot rail 20, hand rail 18 is repositioned into brackets of rail bracket assemblies 24 once again. Each spindle cover 30 on hand rail 18 is rotated into a position where it can receive the free upper end of one of spindles 22 therein. Side walls 60 of spindle 22 are received into gap 58 of spindle cover 30, but may not necessarily extend inwardly into cover 30 to the degree that the uppermost edge thereof abuts the interior surface of the bottom wall 54. Once spindles 22 are engaged between racking assemblies 12 in the hand and foot rails 18, 20, the spindles 22 may be moved slightly from side to side to rotate the spindle covers 30 on the rail pivots 28 and to thereby achieve the correct alignment of spindle 22 relative to hand and foot rails 18, 20. This adjustment also enables the installer to ensure that the spacing between adjacent spindles 22 is kept substantially constant. No fasteners are required to install spindles 22. Additionally, because spindle covers 30 hide the outer ends of spindle 22, the connection between spindles 22 and hand and foot rails 18, 20 is more aesthetically pleasing. Once all spindles 22 are determined to be in the correct position, the installer snap fits bracket covers 76 (
As shown in
In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention are an example and the invention is not limited to the exact details shown or described.