Background
Railing and fence assemblies can include combinations of vertical posts, horizontal rails (e.g., top and bottom rails), and vertical pickets. Horizontal rails can extend between the posts with vertical pickets that can be mounted between the posts, secured by the rails. In such assemblies, supporting hardware (e.g., screws, brackets, fasteners, nails, etc.) is often used to secure the rails to each picket in the railing assembly. Depending on the number of pickets in the railing assembly, the amount of supporting hardware necessary to install a railing assembly can be substantial. The use of a substantial amount of supporting hardware increases the difficulty in assembling the railings and fences, often making the assembly frustrating and time-consuming. Further, the requisite inclusion of supporting hardware in railing and fence assemblies increases the costs of such assemblies. Accordingly, railing and fence assemblies, and methods for assembling railings and fences requiring minimal supporting hardware are desirable that are more efficient to assemble and less expensive to manufacture and/or purchase.
SUMMARY
One aspect relates to a railing assembly in which a rail is coupled to one or more pickets using an interference fit. The interference fit is achieved by engaging members in the rail that secure the rail to each picket after each picket is inserted in a passage in the rail. The railing assembly may also include a second rail having engaging members configured to couple the second rail with the opposing end of each picket using an interference fit. One or both of the rails may further include a clip having one or more openings, each opening configured to allow a picket to pass through prior to coupling with the rail. The railing assembly may further include one or more posts.
Another aspect relates to a method for assembling an interference-fit based railing assembly. The method includes coupling a rail having engaging members to one or more pickets, wherein the one or more pickets is coupled to the railing using an interference fit.
These illustrative aspects are not mentioned to limit or define the invention, but to provide examples to aid understanding of the inventive concepts disclosed herein. Other features and aspects will become apparent upon review of the entire disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cutaway end view of a railing assembly according to one aspect.
FIG. 2 is a cutaway end view of a top rail of a railing assembly according to one aspect.
FIG. 3 is a cutaway end view of a top rail of a railing assembly according to one aspect.
FIG. 4 is a cutaway end view of a top rail of a railing assembly according to one aspect.
FIG. 5 is a cutaway end view of a bottom rail of a railing assembly according to one aspect.
FIG. 6 is a perspective view of a top rail of a railing assembly according to one aspect.
FIG. 7 is a perspective view of a bottom rail of a railing assembly according to one aspect.
FIG. 8 is a perspective view of a rail clip according to one aspect.
FIG. 9 is a diagram of a post of a railing assembly according to one aspect.
FIG. 10 is a diagram of a rail bracket according to one aspect.
FIG. 11 is a diagram of a rail bracket according to one aspect.
FIG. 12 is a diagram of a post cap according to one aspect.
FIG. 13 is a diagram of a post base according to one aspect.
FIG. 14 is an exploded view of an example of a railing assembly according to an aspect.
FIG. 15 is a perspective view of a railing assembly according to an aspect.
FIG. 16A is a side view of a rail according to an aspect.
FIG. 16B is a perspective view of a rail according to an aspect.
FIG. 17 is a cutaway end view of a railing assembly according to an aspect.
DETAILED DESCRIPTION
The present disclosure relates to an interference fit-based interlocking fencing and railing assembly. For purposes of the present disclosure, fencing assembly and railing assembly may be used interchangeably. The railing assembly includes components that can interlock via an interference fit to create a rigid and secure assembly without the use of supporting hardware (screws, brackets, fasteners, nails, etc.). An interference fit, also known as a press fit or friction fit, can include coupling two components together using a retaining force (e.g., friction). For some metal components (e.g., extruded aluminum), the force that retains the parts together may be greatly increased by one components compressing against another. Other component materials, such as plastics, may also be used. An interference fit can be achieved by shaping complementary mating components so that one component (or both) slightly bends or is compressed when joined together. The interference fit of the components can allow the railing assembly to be easy to assemble yet durable and difficult to disassemble unintentionally.
The directional terms used in this disclosure (e.g., top, bottom, vertical, horizontal, etc.) are for simplicity of discussion to refer to examples of orientations of the railing assembly or components thereof. The terms are not used to limit the railing assembly or its components to any particular orientation. For example, a “bottom” portion of the railing assembly can refer to a portion of the railing assembly that is closest to the ground, that is farthest away from the ground, or that is parallel to the ground and on substantially the same plane with respect to the ground as a “top” portion in connection with a horizontal orientation. Generally, a “top” portion and a “bottom” portion can be a first end portion and a second, opposing end portion of a railing assembly.
FIG. 1 is a cut-away end view of a railing assembly 100 according to one aspect. The railing assembly 100 includes a top rail 102 and a bottom rail 104 coupled by an interference fit to opposing ends of a picket 106. The top rail 102 includes engaging members 108a, 108b configured to couple the top rail 102 to the picket 106 using an interference fit with one end of the picket 106. The bottom rail 104 includes engaging members 110a, 110b configured to couple the bottom rail 104 to the picket 106 using an interference fit with the opposing end of the picket 106. The engaging members 108a, 108b and 110a, 110b can each be spaced, shaped, and provided resiliency to apply a restraining force against the picket 106 when the picket 106 is between the respective engaging members 108a, 108b and 110a, 110b. The top rail 102 and the bottom rail 104 can be coupled using the picket 106 using an interference fit without the need for supporting hardware. The picket 106 can include a substantially hollow structure defined by four, equal-width sidewalls oriented at right angles. For example, the picket 106 can include a square-shaped extruded aluminum tube. In some aspects, the picket 106 is forcibly slid between the engaging members 108a, 108b and 110a, 110b to couple the top rail 102 and the bottom rail 104 to the picket 106. Railing assemblies according to other examples may include a top rail or a bottom rail (but not both) that can couple to a picket using an interference fit.
The top rail 102 is shown in greater detail in FIG. 2. The top rail 102 includes a top cap 202 that forms the upper surfaces of the top rail 102. The top rail 102 may also include a top clip 204. As described in FIG. 1, the top rail 102 may include engaging members 108a, 108b. The engaging members 108a, 108b are positioned to define a passage 206 sized to receive a picket. The passage 206 defined by the engaging members 108a, 108b may be tapered such that increasing force is applied to the picket as it enters the passage. The engaging members 108a, 108b may have thicker ends. The thicker ends of the engaging members 108a, 108b may be shaped to provide additional force to the picket once it enters the passage. For example, FIGS. 1 and 2 illustrate engaging members having bulbous ends that provide additional force to the picket 106 in passage 206.
The engaging members 108a, 108b can be shaped to define channels 208a, 208b for coupling with the top clip 204. The top clip 204 may include clip tabs 210a, 210b that can be slidably received by the channels 208a, 208b, respectively, for coupling the top clip 204 to the top rail 102. The clip tabs 210a, 210b can be prevented from decoupling from the top rail 102 after being slidably received by the channels 208a, 208b.
In one example of coupling the top clip 204 to the top rail 102, the top clip 204 is slidably received by the top rail 102 by horizontally sliding the top clip 204 into the channels 208a, 208b at a first end of the top rail 102 until the top clip 204 reaches a second end of the top rail 102. This may, alternatively, be accomplished by vertically sliding the clip tabs 210a, 210b into the channels 208a, 208b, respectively, starting from the bottom end of the top rail 102 (e.g., the end of the top rail 102 opposite the top cap 202). Coupling of the top clip 204 to the top rail 102 may require the application of force using a tool (e.g., a mallet).
The top clip 204 can include an opening 212 sized for allowing a picket to pass through the opening 212 and into the passage 206. When inserted into the passage, the movement of the picket can be substantially restricted by friction applied using an interference fit from the engaging members 108a, 108b. The top rail 102 may also include a bracing member 214 that can provide additional rigidity to the top rail 102 and prevent a picket from progressing beyond the bracing member 214 when the picket is inserted into the passage 206.
The top cap 202 of the top rail 102 can be decorative or ergonomic, depending upon the application of the railing assembly (e.g., fence, railing for stairs, etc.). The style of a top cap can be independent of the structure and spacing of the engaging members 108a, 108b, the passage 206, and the channels 208a, 208b. In the example shown in FIG. 2, the top cap 202 is shaped in a “Dixie” style. There are other styles that can be used. FIG. 3 depicts an example of a top rail 302 having a top cap 304 that is a “Round” style. FIG. 4 depicts an example of a top rail 402 with a top cap 404 that is a “Mailbox” style.
FIG. 5 shows the bottom rail 104 of FIG. 1 in greater detail. The bottom rail 104 includes a bottom cap 504 that forms the outer surfaces of the bottom rail 104.
The bottom rail may also include engaging members 110a, 110b positioned to define a passage 506 sized to receive a picket. The engaging members 110a, 110b may also be shaped to define channels 508a, 508b for coupling with a bottom clip 504. The bottom clip 504 may include clip tabs 510a, 510b that can be slidably received by the channels 508a, 508b, respectively, for coupling the bottom clip 504 to the bottom rail 104. The clip tabs 510a, 510b can be prevented from decoupling from the bottom rail 104 after being slidably received by the channels 508a, 508b, respectively. Coupling of the bottom clip 504 to the bottom rail 104 may be accomplished in a manner similar to the coupling of the top clip 204 to the top rail 102.
The bottom clip 504 can also include an opening 512 sized for allowing a picket to pass through the opening 512 and into passage 506. When inserted into the passage, the movement of the picket can be substantially restricted by friction applied using an interference fit from the engaging members 110. Like the top cap 202 of the top rail 102, the bottom cap 502 of the bottom rail 104 can be decorative or ergonomic, depending upon the application of or surface for the railing assembly. The style of a bottom cap can be independent of the structure and spacing of the engaging members 110a, 110b, the passage 506, and the channels 508a, 508b.
In certain aspects, the railing assembly may include more than one picket. In such aspects, the top rail or bottom rail (or both) may be coupled to each picket using engaging members configured to couple the rail(s) to the pickets using an interference fit for each picket.
FIGS. 6 and 7 show a perspective view of the top rail 102 and bottom rail 104, respectively. The cross-sectional shape of the top rail 102 and bottom rail 104 can be any desirable length. For example, a die can be used to extrude the rail material to a predetermined length. In one aspect, the rails can be manufactured in a standard length, e.g., ten feet, and can later be reduced in length at an on-site location for custom installation.
In at least one aspect where the railing assembly includes the top rail 102 coupled to more than one picket, each picket may be arranged in parallel with the others and perpendicular to the top rail. The engaging members 108a, 108b of the top rail 102 (and the passage 206) extend along the predetermined length of the top rail 102 and are configured to couple the top rail to each picket using an interference fit. Depending upon the application of or surface for the railing assembly, or for other reasons (e.g., the shape of the top rail), the arrangement of the pickets relative to each other and to the top rail may vary. For example, where the railing assembly is used as railings to a staircase, each picket may be arranged in parallel with other pickets, but each picket may be coupled to the top rail using an interference fit at an angle corresponding to the slope of the staircase. In another example, where the railing assembly is a fence used on a curved surface, the pickets may be arranged perpendicular to the surface rather than parallel to the other pickets.
FIG. 8 shows a perspective view of a clip for a railing assembly. The clip may be used as a top clip 204 or as a bottom clip 504. The clip 204/504 includes multiple openings 212/512, each opening configured to allow a picket to pass through. Where the clip 204/504 is coupled to the top rail 102 or the bottom rail 104, the rail 102/104 may be coupled to a picket by passing the picket through the opening 212/512 in the clip 204/504 and passing the picket through the passage 206/506. Use of a clip in the railing assembly may provide enhanced stability to the assembly. Further, the clip allows for easier installation of the railing assembly as the spacing between the pickets is pre-defined by the openings in the clip.
FIG. 9 shows a post 900 that may be included in some aspects of a railing assembly. The post 900 may be located at a first end of a rail, at a second end of a rail, or at both ends of a rail. In some aspects, the post 900 may be made of the same material as the pickets of the railing assembly and may be similar in shape to the pickets, though may have thicker sidewalls and a greater diameter (or cross-section) and length than the pickets. In some aspects, one or both ends of the post 900 may be configured to be coupled to a rail using an interface fit. In such aspects, the diameter or cross-section of the end(s) of the post may be of a different diameter or cross-section than the other portions of the post. For example, the post of a railing assembly may have one or both ends identical in shape and size to the pickets of a railing assembly, but the remainder of the post may have a greater diameter (or cross-section), as illustrated by post 1514b in FIG. 15. In this configuration, the end of the post may be slidably received by the top rail.
FIGS. 10 and 11 show rail brackets 1000 and 1100. Rail brackets may provide support for the rails in a railing assembly and, further, provide enhanced stability for the railing assembly. In some aspects, a rail may include a rail bracket 1000/1100 coupled to one or both ends of the rail. The rail bracket may include a mating portion 1002/1102 and a back portion 1004/1104. The mating portion 1002/1102 may be configured to join with the end of a rail. For example, the mating portion 1002/1102 may be slidably connected, adhered, or fastened to the end of a rail. The back portion 1004/1104 may be configured to serve as a stopper for a rail joined to the mating portion 1002/1102. The side of the back portion 1004/1104 opposite the mating portion 1002/1102 may be left bare or may be connected, adhered, or fastened to a post or to a fixture to which the railing assembly is joined (e.g., a wall).
In FIG. 10, the mating portion 1002 of rail bracket 1000 is shaped in the “Dixie” style complementary to the “Dixie” style of the top cap 202 of the top rail 102 such that the rail bracket 1000 may be slidably connected, adhered, or fastened to the end of the top rail 102. FIG. 11 shows a rail bracket 1100 configured to couple to the end of bottom rail 104. The mating portion 1102 of rail bracket 1100 is shaped such that the rail bracket 1000 may be slidably connected, adhered, or fastened to the end of the bottom rail 104.
FIG. 12 shows one aspect of a post cap 1200 that may be included on a post 900. The post cap 1200 may be used to cover the top end of a post and may be configured in a number of shapes. In the aspect shown, the post cap 1200 includes sidewalls 1202 forming a square shape and includes a pyramid-shaped upper portion 1204 connected to the sidewalls 1202. The post cap 1200 can prevent rainwater or other items from entering inner portions a hollow post 900. The post cap 1200 may be shaped such that the post cap 1200 may be slidably connected, adhered, or fastened to the top end of a post 900.
FIG. 13 shows one aspect of a post base 1300 for coupling to a post 900. The post base includes post base engaging members 1302a, 1302b and a bottom portion 1304. The post base 1300 can be used to mount or affix a post to another surface, such as the ground or a concrete slab. The post base engaging members 1302a, 1302b may be positioned and shaped such that the post base 1300 may be slidably connected, adhered, or fastened to the bottom end of a post 900. In some aspects, the post base engaging members 1302a, 1302b may be positioned and shaped such that the post base 1300 may be coupled to the bottom end of a post 900 using an interference fit. The bottom portion 1304 may be shaped complementary to shape of a post 900 such that the post base 1300 may cover the bottom of the post 900. In some aspects, the bottom portion 1304 may be sized such that a post 900 coupled to the post base 1300 may stand vertically without supporting components.
FIG. 14 shows an exploded (or disassembled) view of a railing assembly 1400 according to one aspect. In this aspect, the railing assembly 1400 includes a top rail 1402, a bottom rail 1404, multiple pickets 1406, a top clip 1408a having openings (not shown), a bottom clip 1408b having openings (not shown), and two posts 1410, each having post brackets 1412a, 1412b for the top rail 1402 and bottom rail 1404, a post cap 1414, and a post base 1416. Assembling the components of a railing assembly may be accomplished in any order.
FIG. 15 shows a perspective view of an assembled railing assembly 1500 according to another aspect. In this aspect, the railing assembly 1500 includes a top rail 1502, two bottom rails 1504a, 1508b, multiple pickets 1506, a top clip 1508a, two bottom clips 1508a, 1508b, and three posts 1510a-c, each having post brackets 1512a-e for the bottom rails and a post base 1514a-c.
In some aspects, the interference fit used to couple the top rail 102 or bottom rail 104 to a picket may be reinforced by a mechanical locking feature. For example, FIGS. 16A and 16B show a picket 1600 having slots 1602. The slots 1602 may be grooved into opposing surfaces of the picket 1600 and may be positionable to align with the engaging members 108a, 108b of the top rail 102 when the top rail 102 is coupled to the picket 1600 or with the engaging members 110a, 110b of the bottom rail 104 when the bottom rail 104 is coupled to the picket 1600.
FIG. 17 shows a cutaway view of the top rail 102 coupled to the picket 1600. The movement of the picket 1600 may be substantially restricted by friction applied using an interference fit from the engaging members 108a, 108b. In addition to the interference fit, movement of the picket 1600 may be further restricted by aligning the slots 1602 of the picket 1600 such that the engaging member 108a of the top rail 102 is aligned with slot 1602a of the picket 1600 and engaging member 108b of the top rail 102 is aligned with slot 1602b of the picket 1600. The engaging members 108a, 108b can be provided resiliency to apply a restraining force against the picket 1600 to mechanically lock the engaging members 108a, 108b into the slots 1602 of the picket 1600.
The foregoing description of the examples, including illustrated examples, of the invention has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof can be apparent to those skilled in the art without departing from the scope of this invention. The illustrative examples described above are given to introduce the reader to the general subject matter discussed here and are not intended to limit the scope of the disclosed concepts.
Patent Application
20150300041
