POST MOUNT CABLE RAIL INSTALLATION SYSTEM

FIELD OF THE INVENTION

The present invention relates generally to railing systems and relates more specifically to support hardware for use in railing installations.

BACKGROUND OF THE DISCLOSURE

Post mounts are frequently used in the construction of decks, porches, stairs, and other structures that include railings. FIG. 1, for example, is a schematic illustration of a portion of an example railing system 100, including a post mount 108. The railing system 100 comprises a railing 102, a support surface 104, and a plurality of posts 106₁-106_n(hereinafter collectively referred to as “posts 106”). Generally, the rail 102 is supported in a spaced-apart relation relative to the support surface 104 by the posts 106.

In order to mount the posts 106 to the support surface 104 (which may comprise, for example, wood or concrete) in a substantially invisible manner (i.e., little or no outwardly visible hardware), post mounts are often first installed in the support surface 104. For example, the post 106₁is mounted to the support surface via a post mount 108 (illustrated in phantom). Specifically, the post mount 108 is fastened to the support surface 104 in a secure manner, and the hollow post 106₁is then slipped over the post mount 108, like a sleeve. In this manner, the post 106₁is supported securely by the support surface 104 and in turn provides secure support for the railing 102.

Some railing systems for decks, stairs and other applications include cable rails, formed of rod cables or braided metal cables, with or without plastic sheathings. The cable rails are often used in conjunction with rigid railings and posts, which may be fabricated from plastics such as polyvinyl chloride (PVC) or pressure treated lumber, e.g., a 4×4 post. FIG. 2 illustrates, for example, a schematic illustration of a portion of an additional example railing system 200 that includes cables or “cable rails” 230₁-230₃. The railing system 200 also includes a railing 202, a support surface 204, and a plurality of posts 206₁-206_n(hereinafter collectively referred to as “posts 206”). Typically, an installer is required to drill a series of holes 218 in the posts 206 in order to install the cables 230₁-230₃. The cables are then passed through the holes 218 and affixed to the end posts, e.g., posts 206₁and 206_n, with fasteners 220₁-220₅.

In some instances, a fastener may comprise a flange attached to the end of the cable such that the cable cannot be pulled out of the post to which it is affixed, e.g., fasteners 220₁-220₄. In other instances, a fastener may comprise a threaded bolt and a nut, e.g., fastener 220₅. The threaded bolt and nut may secure the cable 230₁in place and may further be tightened to provide a desired tension in the cable 230₁. In another example, cable 230₂may be tensioned by a tensioner 240, such as a turnbuckle or similar mechanism. As illustrated in connection with cable 230₃, a cable may further be affixed to a wall or other vertical surface, e.g., wall 250 where the railing 202 ends. For example, an end of cable 230₃may be hooked to a screw eye 260 that is threaded into the wall 250.

SUMMARY OF THE INVENTION

Post mount cable rail systems and methods for installation are disclosed. An example post mount system may include a support pipe for securing the post mount system to a support surface and a screw block including a central opening formed in a lengthwise direction of the screw block. The central opening is sized to fit over the support pipe. The screw block may be devoid of pre-fabricated openings passing in directions that intersect the central opening.

Another example post mount system includes a support pipe for securing the post mount system to a support surface. A first elongate opening is formed in a first side of the support pipe, along the length of the support pipe. A second elongate opening is formed in a second side of the support pipe, along the length of the support pipe. The second side is positioned opposite from the first side such that a passage through the support pipe is defined by the first elongate opening and the second elongate opening.

In one example, a method for installing a post mount for a cable rail system includes securing a support pipe of the post mount to a support surface of the cable rail system. A screw block is fitted over the support pipe. The screw block includes a central opening formed in a lengthwise direction of the screw block. The central opening is sized to fit over the support pipe, and the screw block is devoid of pre-fabricated openings passing in directions that intersect the central opening. A piece of hardware for securing a cable rail is lagged directly into the screw block, and the cable rail is secured to the piece of hardware.

In another example, a method for installing a post mount for a cable rail system includes securing a support pipe of the post mount to a support surface of the cable rail system. The support pipe includes a first elongate opening formed in a first side of the support pipe, along a length of the support pipe and a second elongate opening formed in a second side of the support pipe, along the length of the support pipe. The second side is positioned opposite from the first side, such that a passage through the support pipe is defined by the first elongate opening and the second elongate opening. A cable rail is passed through the passage, from the first elongate opening to the second elongate opening.

BRIEF DESCRIPTION OF THE DRAWINGS

The teachings of the present disclosure can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:

FIG. 1 is a schematic illustration of a portion of an example railing system, including a post mount;

FIG. 2 is a schematic illustration of a portion of an example railing system, including a plurality of cable rails;

FIG. 3 illustrates a schematic view of a first example of a post mount, according to the present disclosure;

FIG. 4 illustrates an exploded view of portions of the post mount of FIG. 3, in order to show features not clearly depicted in FIG. 3;

FIG. 5 illustrates a schematic view of a second example of a post mount, according to the present disclosure

FIG. 6 illustrates an exploded view of portions of the post mount of FIG. 5, in order to show features not clearly depicted in FIG. 5;

FIG. 7 illustrates an exploded view of portions of an alternative support pipe that may be used in conjunction with the post mount of FIG. 5;

FIG. 8 illustrates a first example post mount cable rail system according to the present disclosure;

FIG. 9 illustrates a second example post mount cable rail system according to the present disclosure; and

FIG. 10 is a flow diagram illustrating one embodiment of a method for installing a post mount cable rail system, according to the present disclosure.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.

DETAILED DESCRIPTION

The present disclosure describes a novel post mount cable rail system and method for installing such a system. The use of post mounts is favored in many applications because it allows a series of posts (and a railing) to be fixed to a support surface in a clean and attractive manner, with little or no outwardly visible hardware. An example post mount system is described in U.S. Pat. No. 8,579,243 titled “METHOD AND APPARATUS FOR INSTALLING A POST MOUNT” and issued on Nov. 12, 2013, the entirety of which is incorporated herein by reference.

Likewise, the use of cable rails is also favored in many applications. For example, cable rails are often used under solid railings where additional security is necessary, such as on a raised deck where it is desired to prevent people and large objects from falling off the deck. Solid structures, such as additional pipes arranged in rows, columns or other designs under the railing are sometimes used. Large solid pieces of glass are also used in many instances. But the former can significantly block a view while the latter can be quite expensive. Thus, cable rails are often a good choice in the circumstances.

However, where a cable rail system is desired to be used in connection with a post mount system, the installer is faced with a laborious and error-prone process. For instance, the installer must drill holes for a cable rail system through each post as well as through the post mount inside the post. The installer must also correctly form the holes through the post and through the post mount such that the holes are aligned, in order to easily pass a cable through both the post and the post mount. In addition, the cables are then secured to the outside of a post, which defeats one of the most important features of a post mount system, i.e., the ability to hide hardware.

Accordingly, the present disclosure provides a post mount system that can be used in conjunction with cable rails while retaining the ability to hide hardware as in previous post mount systems. The post mount system of the present disclosure, referred to herein as a “post mount cable rail system” also allows for an easy and fast installation. Examples of the disclosure include a solid sleeve or screw block that fits over a support pipe of a post mount. A post may then be fitted over the screw block. This arrangement allows cable hardware to be lagged directly into the screw block, without having to lag or pre-drill holes into the support pipe and without having to pre-drill and align holes in the screw block.

Other examples of the disclosure include a support pipe having elongate slits or openings formed in opposing sides of the support pipe. This arrangement allows a cables to pass through the support pipe at any angle, without the need for pre-drilled or precisely aligned holes. In further examples, the same advantage can be achieved by forming the support pipe in two pieces that are spaced apart from each other with enough distance to allow a cable to pass between them. A post mount of this example is suitable for use in both level installations (e.g., deck railings) and angled installations (e.g., stair railings), since it allows the cable to pass through the posts at any angle.

FIG. 3 illustrates a schematic view of a first example of a post mount 300, according to the present disclosure. The post mount of FIG. 3 may be especially suitable for use in mounting end posts of a cable rail system (i.e., posts at which the cable terminates or passes through only one side), although it may also be used for intermediary posts (i.e., posts at which the cable passes all the way through). FIG. 4 illustrates an exploded view of portions of the post mount 300 of FIG. 3, in order to show features not clearly depicted in FIG. 3. The following description refers to features shown in both figures.

Notably, the post mount 300 includes a support pipe 320 with a base 324 that allows the support pipe 320 to be fixed to a support surface 360. The base 324 may be attached to the support pipe 320 by welding, by mechanical fasteners, or by other fastening means. Both the support pipe 320 and the base 324 may be formed from a metal such as aluminum or steel, a metal alloy, a plastic such as PVC, fiberglass, or a composites, or other materials. In one example, the support pipe 320 comprises a square pipe. It should be noted that the present disclosure primarily describes examples with square pipes and posts. However, the present disclosure is not so limited. For example, in other, further and different embodiments, pipes and posts of rectangular cross section, hexagonal cross section, circular cross section, and so forth may alternatively or additionally be deployed. In addition, the cross sectional shape of a post and the pipe(s) of a post mount need not comprise the same shape. For example, a hexagonal post may be used while the mounting pipe and/or support pipe of the post mount may comprise pipes with square cross sections. Furthermore, although the support pipe illustrated in FIG. 4 is hollow, solid support pipes could also be used. In any case, in one example, the support pipe 320 is devoid of any pre-fabricated holes for mounting a cable rail.

In accordance with the present disclosure, post mount 300 also includes a sleeve or screw block 310 sized slide over the support pipe 320. In one example, the screw block 310 is a solid or reinforced hollow (e.g., similar to the support blocks disclosed in U.S. Pat. No. 8,579,243) sleeve formed of a plastic, such as PVC, fiberglass, or a composite, or any other material into which cable hardware can be directly lagged. The screw block 310 includes an opening or hollow central passage 330 in its lengthwise direction, through which the support pipe 320 passes. However, in one example, the screw block 310 is devoid of openings or holes passing in directions that intersect with the lengthwise central passage (e.g., such as pre-fabricated holes formed in the sides for securing cable hardware). In one example, the outer perimeter of the support pipe 320 is sized slightly smaller than the inner perimeter of the central passage 330, such that the screw block 310 can be slid snugly over the support pipe 320 without binding.

During installation of a post mount cable rail system, the screw block 310 may be fitted over the support pipe 320, and hardware, e.g., for securing an end of a cable, can be lagged directly into the screw block 310. Before lagging the hardware into the screw block 310, a post 365 (i.e., the outwardly visible sleeve, which may or may not include pre-drilled holes) can be fitted over the screw block 310.

FIG. 5 illustrates a schematic view of a second example of a post mount 500, according to the present disclosure. The post mount of FIG. 5 may be especially suitable for use in mounting middle or intermediate posts of a cable rail system (i.e., posts at which the cable passes all the way through), although it may also be used for end posts (i.e., posts at which the cable terminates or passes through only one side). FIG. 6 illustrates an exploded view of portions of the post mount 500 of FIG. 5, in order to show features not clearly depicted in FIG. 5. The following description refers to features shown in both figures.

Notably, the post mount 500 includes a support pipe 520 with a base 524 that allows the support pipe 320 to be fixed to a support surface 560. The base 524 may be attached to the support pipe 520 by welding, by mechanical fasteners, or by other fastening means. Both the support pipe 520 and the base 524 may be formed from a metal such as aluminum or steel, a metal alloy, a plastic such as PVC, fiberglass, or a composites, or other materials. In one example, the post mount 500 further includes support blocks 555 which may be fitted to one or both of the ends of the support pipe 520. In particular, the support blocks 555 allow a post 565 to be slipped over the post mount 500 such that the post 565 is snugly supported by the support blocks 555 and does not wobble. The support blocks 555 may be formed according to the embodiments described in U.S. Pat. No. 8,579,243, the entirety of which is incorporated by reference herein.

In one example, the support pipe 320 comprises a square pipe that includes at least two elongate openings or slits 510 which are pre-fabricated along the length of the support pipe 520. It should be noted that the present disclosure primarily describes examples with square pipes and posts. However, the present disclosure is not so limited. For example, in other, further and different embodiments, pipes and posts of rectangular cross section, hexagonal cross section, circular cross section, and so forth may alternatively or additionally be deployed. In addition, the cross sectional shape of a post and the pipe(s) of a post mount need not comprise the same shape. For example, a hexagonal post may be used while the mounting pipe and/or support pipe of the post mount may comprise pipes with square cross sections. Furthermore, although the support pipe illustrated in FIG. 5 is hollow, solid support pipes could also be used.

In any case, in one example the slits 510 are formed in pairs that extend along the length of the support pipe 520 on opposing sides (non-adjacent sides). In particular, for cable rail applications it is necessary to pass the cables through the support pipe 520 so that the cables can pass from one side of a post to the other. In one example, the slits 510 are formed on at least two opposing sides of the support pipe 520. In another example, the slits 510 are formed on all four sides of a square support pipe 520, e.g., two sets of slits in two opposing sides. This supports applications where the post mount 500 may be used in an L-shaped corner, a T-shaped intersection, an X-shaped intersection, and so forth.

During installation of a post mount cable rail system, a cable may be passed through the opposing slits 510 in the support pipe 520. Before passing the cable through, a post 565 (i.e., the outwardly visible sleeve, which may or may not include pre-drilled holes) can be fitted over the support pipe 520 and support blocks 555. Because the slits 510 extend along the length of the support pipe 520, the cable is able to pass through the support pipe 520 at any angle, with requiring holes to be pre-drilled into the support pipe and aligned with corresponding holes in the post 565. This makes the post mount 520 especially useful for angles installations, such as stairway railings.

FIG. 7 illustrates an exploded view of portions of an alternative support pipe 720 that may be used in conjunction with the post mount 500 of FIG. 5. The support pipe 720 may be formed from a metal such as aluminum or steel, a metal alloy, a plastic such as PVC, fiberglass, or a composites, or other materials. In one example, the support pipe 720 comprises a square pipe that is formed in at least two separate pieces 725₁and 725₂(hereinafter collectively referred to as “pieces 725”). The pieces 725 are spaced apart from each other to define elongate openings or slits 710 along the length of the support pipe 720. It should be noted that the present disclosure primarily describes examples with square pipes and posts. However, the present disclosure is not so limited. For example, in other, further and different embodiments, pipes and posts of rectangular cross section, hexagonal cross section, circular cross section, and so forth may alternatively or additionally be deployed. In addition, the cross sectional shape of a post and the pipe(s) of a post mount need not comprise the same shape. For example, a hexagonal post may be used while the mounting pipe and/or support pipe of the post mount may comprise pipes with square cross sections. Furthermore, although the support pipe illustrated in FIG. 7 is hollow, solid support pipes could also be used.

In any case, in one example the slits 710 are formed in pairs that extend along the length of the support pipe 720 on opposing sides (non-adjacent sides). In one example, the slits 710 are formed on at least two opposing sides of the support pipe 720 (i.e., such that the support pipe 720 is formed in at least two separate pieces 725). In another example, the slits 710 are formed on all four sides of a square support pipe 720, e.g., two sets of slits in two opposing sides (i.e., such that the support pipe 720 is formed in at least four separate pieces 725). This supports applications where the post mount 500 may be used in an L-shaped corner, a T-shaped intersection, an X-shaped intersection, and so forth.

FIG. 8 illustrates a first example post mount cable rail system 800 according to the present disclosure. In particular, FIG. 8 illustrates a level installation of the post mount cable rail system 800, such as may be suitable for decking. The system 800 includes a railing 802 and posts 806₁-806₃(hereinafter collectively referred to as “posts 806”) secured to a support surface 804 using a plurality of post mounts 805₁-805₃(hereinafter collectively referred to as “post mounts 805”). In one example, the end posts (i.e., posts 806₁and 806₃in FIG. 8) use post mounts similar to that illustrated in FIGS. 3-4 (i.e., including a screw block fitted over a support pipe), while the middle posts (i.e., post 806₂in FIG. 8) use post mounts similar to that illustrated in FIGS. 5-7 (i.e., including a support pipe with at least two elongate slits formed therein and one or more support blocks).

Notably, the posts 806₁-806₃may all have respective series of holes for allowing cables to pass through. However, for ease of illustration, such holes are not shown in FIG. 8. It should also be noted that at least some of the holes from one post to the next may all be aligned (i.e., in a straight line or a substantially straight line) such that a cable can be extended along a rail through a number of posts 806 and posts mounts 805.

As illustrated in FIG. 8, hardware such as threaded anchors may be lagged directly into the screw blocks of the post mounts 805₁and 805₃positioned at the ends of the system 800 and used to secure the ends of cables making up the railing 802. However, for posts 806 that do not need to secure a hardware item, the post mount 805 may include a pair of elongate slits that allows the cable to pass right through at any angle, similar to the post mount 805₂. Therefore, an entire railing system can be installed without requiring holes for cable pass-through to be predrilled into or pre-aligned in any of the support pipes. For example, for a single straight railing with ten posts, only two post mounts using a screw block (e.g., similar to the post mount illustrated in FIGS. 3-4) may be required (one for each end), while eight post mounts using support pipes with elongate slits (e.g., similar to the post mount illustrated in FIGS. 5-7) may be required (in between the ends). Nevertheless, as described above, in another embodiment a post mount including a screw block may optionally be installed in a mid-span post mount, e.g., post mount 805₂. For example, the railing 802 may be joined to or meet another rail in a T-shaped intersection at post 806₂, or it may be desired to install decorative or functional hardware on one of the sides of the post 806₂through which the cables do not pass.

FIG. 9 illustrates a second example post mount cable rail system 900 according to the present disclosure. In particular, FIG. 9 illustrates an angled installation of the post mount cable rail system 900, such as may be suitable for stairs. The system 900 includes a railing 902 and posts including a middle or intermediate post 906 secured to a support surface 904 using a post mounts 905. In one example, the end posts (i.e., not shown in FIG. 9) use post mounts similar to that illustrated in FIGS. 3-4 (i.e., including a screw block fitted over a support pipe), while the middle posts including post 906 use post mounts similar to that illustrated in FIGS. 5-7 (i.e., including a support pipe with at least two elongate slits formed therein and one or more support blocks).

Notably, the posts 906 may all have respective series of holes for allowing cables to pass through. However, for ease of illustration, such holes are not shown in FIG. 9. It should also be noted that at least some of the holes from one post to the next may all be aligned (i.e., along an angled line) such that a cable can be extended along a rail through a number of posts and posts mounts.

As illustrated in FIG. 9, use of a post mount 905 that is similar to the post mount illustrated in FIGS. 5-7 allows the cable rail 902 to pass through the intermediate posts and post mounts at any angle, without requiring holes in the corresponding post mounts to be pre-drilled and pre-aligned.

FIG. 10 is a flow diagram illustrating one embodiment of a method 100 for installing a post mount cable rail system, according to the present disclosure. For example, the method 1000 may be used to install at least a portion of the post mount cable rail systems 800 or 900 illustrated in FIGS. 8 and 9.

The method 1000 is initiated in step 1005 and proceeds to optional step 1010. In step 1010, a first support pipe is secured to a support surface. For example, the base of the first support pipe (which may be attached to the first support pipe by welding, mechanical fasteners, or other means) may be attached (e.g., by mechanical fasteners) to a support surface such as the floor of a deck or the run of a stair. In one example, the first support pipe comprises a hollow or solid pipe having a square-shaped cross section.

In optional step 1020 (illustrated in phantom), a screw block is fitted over the first support pipe. For example, the screw block may comprise a solid or reinforced hollow sleeve formed of a plastic, such as PVC, fiberglass, or a composite, or any other material into which cable hardware can be directly lagged. The screw block includes a hollow central passage through which the first support pipe passes. Collectively, the first support pipe and the screw block comprise a first post mount unit. The first post mount unit may be suitable for use, for example, to mount a post that it positioned at an end of a railing (e.g., a post to which an end of a cable rail is secured).

In one example, optional steps 1010 and 1020 are performed together, meaning that if step 1010 is performed, then step 1020 is performed as well.

In optional step 1030, a second support pipe is secured to the support surface. For example, the base of the second support pipe (which may be attached to the second support pipe by welding, mechanical fasteners, or other means) may be attached (e.g., by mechanical fasteners) to another part of the support surface (e.g., another part of the floor of a deck or the run of another stair). In one example, the second support pipe comprises a hollow or solid pipe having a square-shaped cross section, where elongate slits are formed along the lengths of at least two opposing sides of the pipe. In another example, the second support pipe comprises a hollow or solid pipe having a square-shaped cross section, where the pipe is formed in at least two separate pieces that are spaced apart to define a slit or passage between the pieces.

In optional step 1040 (illustrated in phantom), a support block is fitted over one or both ends of the second support pipe. The support block(s) may be formed according to the embodiments described in U.S. Pat. No. 8,579,243, the entirety of which is incorporated by reference herein. Collectively, the second support pipe and the support block(s) comprise a second post mount unit. The second post mount unit may be suitable for use, for example, to mount a post that it positioned mid-span in a railing (e.g., a post through which a cable rail passes completely).

In one example, optional steps 1030 and 1040 are performed together, meaning that if step 1030 is performed, then step 1040 is performed as well.

In step 1050, posts are fitted over the post mounts (i.e., at least the first post mount and the second post mount). In one example, the posts may be pre-drilled with holes through which cable rails may be passed.

In optional step 1060 (illustrated in phantom), hardware for securing an end of a cable rail is lagged directly into the screw block of the first post mount unit. In one example, lagging the hardware directly into the screw block can be accomplished without having to pre-drill threaded holes to accept the hardware into the screw block or the first support pipe. In one example, the hardware comprises an anchor of a cable, or cable rail. In one example, step 1060 may also include securing a cable to the hardware. For instance, the cable and the anchor may first need to be attached to one another prior to the anchor being lagged into the screw block. Alternatively, a cable may be passed through the post of the first post mount unit and secured to the hardware after the hardware is lagged into the screw block. Step 1060 may be performed multiple times, for any end posts that are assembled in a manner similar to that illustrated in FIGS. 3-4

In one example, optional step 1060 is performed when optional steps 1010 and 1020 are first performed. That is, the presence of a screw block fitted over a support pipe makes it possible to lag the hardware directly into the screw block in step 1060.

In optional step 1070 (illustrated in phantom), the cable is passed through the slit in the support pipe of the second post mount unit. For example, step 1060 may comprise securing the cable to an end post via lagging into a screw block, whereas step 1070 involves threading the cable through a support pipe slit in one or more mid-span posts of the post mount cable rail system. Step 1070 may be performed multiple times, for any mid-span posts that are assembled in a manner similar to that illustrated in FIGS. 5-7.

In one example, optional step 1070 is performed when optional steps 1030 and 1040 are first performed. That is, the presence of a slitted support pipe makes it possible to pass the cable through at any angle in step 1070.

In step 1080, the cable is secured to another post, e.g., an end post of the post mount cable rail system. For example, the post to which the cable is secured in step 1080 may include a post mount unit that is assembled using the same or a similar process to that described above in connection with the first post mount unit. In this case, step 1080 may be performed in a manner similar to step 1060.

The method 1000 ends step 1095.

It should be noted that although the method 1000 describes the post mount of FIGS. 3-4 (i.e., including a screw block into which cable hardware can be directly lagged) used in combination with the post mount of FIGS. 5-7 (i.e., including a post mount with a slitted support pipe), these two post mount configurations do not necessarily have to be used in combination. For instance, some or all of the end posts of the post mount cable rail system might include post mounts such as those illustrated in FIGS. 3-4, while some or all of the mid-span posts include post mount units whose support pipes include pre-drilled holes formed in predefined locations for the cable to pass through. Alternatively, some or all of the end posts might include post mount units having pre-drilled and/or threaded support pipes, while some or all of the mid-span posts have post mounts including slitted support pipes. Thus, the post mounts disclosed herein can be used together or in combination with other types of post mounts. As such, in various embodiments, one or more of the above steps of the method 1000 can be deemed as an optional step. Furthermore, operations, steps or blocks of the above described method(s) can be combined, separated, and/or performed in a different order from that described above, without departing from the example embodiments of the present disclosure.

Although various embodiments which incorporate the teachings of the present disclosure have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings. In addition, while various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a claimed embodiment should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

POST MOUNT CABLE RAIL INSTALLATION SYSTEM

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