Patent Application
20180266141
BACKGROUND OF THE DISCLOSURE
Architecture with designs that require a railing have been common for centuries. For example, a deck is a flat surface capable of supporting weight connected to a building. It is customarily constructed outdoors and is often elevated from the ground. Verandas and observation decks are variations on how a deck may be implemented in residential and commercial buildings. Decks usually have post and beam architecture or cantilever construction. Post and beam construction uses posts anchored to piers in the ground. Cantilever decks use floor joists to stabilize the floor. Upon installation, decks must be waterproofed and flashed to minimize significant safety issues.
These structural decks are then enclosed by railings to further ensure safety, and the railings provide an opportunity to add an aesthetic detail to the construction. These railings are available in a variety of forms, though the appropriate railing may depend on what type and design of building is constructed. For example, there are hand railings, deck railings, cable railings, and guard rails. Each of these railings have specific guidelines or requirements for structural strength and height. Railings may also have different height requirements depending on who the principal user of the railing might be, such as an adult, a child, or a person with a disability.
Each railing may also have different requirements depending on which railing type is being used. A cable railing, for example, may provide support while not obstructing someone's view. This results in thinner cable being used for installation. To compensate for the difference in railing, a cable railing requires more rigid frames to counteract the force applied to the end posts by tensioning the cables. Cables must be adhere to building code requirements and provide minimal cable deflection.
Each railing system is made of disparate components tailored to that particular railing system. However, currently, the primary method of installing railing systems is to make the structural connection to the deck after waterproofing and after deck finishes have been installed. Further, a railing is often attached to the posts through a similarly invasive method. This creates a potential failure point for water intrusion, which leads to safety issues and risk of serious injury.
What is needed is a system to secure a structural post prior to waterproofing and prior to deck finishes being installed. Further needed is a railing system that allows for the railing to connect without piercing the railing posts, finished deck, or any underlying waterproofing system. As a result, this limits the problems associated with structural fastening and waterproofing failures. This system can be used to secure railings in its various iterations, secure steps and stairs, and fortify guardrails.
The present disclosure relates to a railing system comprising: a plurality of railing modules, where each railing module comprises a concealed anchor system, a railing post, a retainer cap, and a railing post. The railing system may comprise a stud extending vertically from a support surface. The railing system may comprise a sleeve centered around the stud extending perpendicular to the support surface. The railing system may comprise a railing post configured to fit around the sleeve, where the railing post comprises a bottom opening configured to accept the sleeve and a top opening. The railing system may comprise a retainer cap connector detachably connected and extending vertically from the stud. The railing system may comprise a retainer cap configured to fit into the top opening, where the retainer cap is detachably connected to the retainer cap connector. The railing system may comprise a railing detachably connected to the retainer cap, where the railing connects at least a portion of the plurality of railing modules.
In some aspects, a railing module may further comprise a securing mechanism detachably connected to one or both the stud and the retainer cap connector, where the securing mechanism strengthens the connection between the stud and the retainer cap connector. In some implementations, the railing module may further comprise a shoe configured to fit over the railing post, where the shoe is in contact with the support surface. The railing post may further comprises at least a first flange extending perpendicular to the railing post, where the first flange comprises one or more recesses or openings configured to fit at least one secondary railing detachably connected to at least the portion of the plurality of railing modules. In some embodiments, the plurality of railing modules may comprise at least a first corner railing module, where the first corner railing module comprises at least a second flange extending perpendicular to the railing post, and where a distance between the second flange and the first flange at least partially indicates an angle at the first corner railing module. In some implementations, the first flange may be attached to the railing post. In some aspects, the first flange and the railing post may comprise a single extrusion.
The support surface may comprise a subflooring, where one or both the stud and the sleeve extend through a finish surface. The railing post may be in contact with the finish surface and not in contact with the subflooring. In some aspects, a counter-force mechanism may be detachably connected to a portion of the stud located between the subflooring and the finish surface, where the counter-force mechanism reduces downward force on the finish surface. The stud may be perpendicular to the subflooring and one or both the sleeve and the railing post may be perpendicular to the finish surface. In some aspects, the railing may be oriented parallel to the support surface. In some embodiments, at least one railing module may be oriented at an angle other than perpendicular to the railing post. The railing post may be oriented perpendicular to the support surface.
The retainer cap may comprise an adjustable flange configured to pivot in a predefined angular range relative to one or both the retainer cap connector and the railing. The concealed anchor system may further comprise a base detachably connected to the support surface, where the stud extends vertically from the base. The base may comprise positional indicators. In some aspects, the retainer cap connector may comprise a threaded rod or a tensioned cable. The railing system may comprise a cable railing system, where the railing post may comprise at least one cable flange extending perpendicular from at least one surface of the railing post, where the at least one cable flange is configured to accept a cable connecting at least a portion of the plurality of railing modules.
The accompanying drawings, that are incorporated in and constitute a part of this specification, illustrate several embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure:
The present disclosure provides generally for a railing system. More specifically, the present disclosure relates to a durable and sleek railing system designed to limit deterioration of connection components and connection points, particularly damage that may be caused by exposure to weather elements, such as precipitation, humidity, wind, particulate, or other environmental conditions, as non-limiting examples.
in the following sections, detailed descriptions of examples and methods of the disclosure will be given. The description of both preferred and alternative examples, though thorough, are exemplary only, and it is understood to those skilled in the art that variations, modifications, and alterations may be apparent. It is therefore to be understood that the examples do not limit the broadness of the aspects of the underlying disclosure as defined by the claims.
Referring now to
In some embodiments, the installation may depend on the type of flooring system. For example, where the flooring may comprise a concrete flooring, the base 105 may be attached directly to the top surface of the concrete or may be installed during the concrete pouring, wherein the base 105 may be located within the concrete flooring with the stud 120 extending from the concrete. In some embodiments, the stud 120 may be drilled directly into the flooring, such as concrete, wherein the stud 120 may be further stabilized with a setting material, such as an epoxy. In some aspects, the base 105 may comprise positional indicators 145, such as markings or notches, which may assist in the installation process. For example, the positional indicators 145 may indicate the center of each side of the base 105, which may allow for simplified or easier centering along with chalk alignment lines during installation.
In some embodiments, a counter force mechanism may be used to limit damage that may be caused by unsupported unilateral pressure. As an example, the flooring may comprise a floating wood deck, wherein the wood deck may comprise a sloped subflooring that allows for effective water drainage. The base 105 may be attached to the sloped subflooring with the stud 120 extending through the wood deck. The sleeve 115 may be set at the upper surface of the wood deck, and a counter-force mechanism may be installed under the wood deck to limit sagging. In some aspects, the counter-force mechanism may comprise a nut and washer or bracers between the subflooring and the lower surface of the wood deck.
In some aspects, a threaded rod 125 may extend from the stud 120 to a retainer cap 135, which may allow a railing 140 to be secured to the railing module 100. In some embodiments, a flange nut may be threaded onto the threaded rod 125 to the connection point with the stud 120, wherein the flange nut may lock the threaded rod 125 in place, limiting the chance of loosening over time. In some implementations, a shoe 110 may be fitted at the base of the railing post 130, wherein the shoe 110 may limit directional stress. In some aspects, the respective lengths of the threaded rod 125 and the stud 120 may vary depending on the particular application or flooring type.
In some aspects, not shown, a cable may be used instead of a threaded rod 125, wherein the cable may be anchored to the stud 120 and the retainer cap 135, wherein tightening the cable may create tension sufficient to limit shifting. In some embodiments, such as between the retainer cap 135 and the railing 140, a layer of material may be added to create a seal that may further limit internal exposure to moisture. For example, a rubber layer may create a seal when compressed during the tensioning of the cable or the tightening of the threaded rod.
In some embodiments, one or more the railing post 130 and the railing 140 may be modular, wherein one or both the railing post 130 and the railing 140 may be interchangeable with other versions. For example, homeowners may prefer to change the aesthetic of their home periodically, and a modular embodiment may allow the homeowners to switch their current stainless steel railing with cables to a black railing with glass panels. A modular embodiment may allow for replacement of damaged portions of the railing system without requiring a complete dismantling of the railing system, which may cause damage to the flooring and may require a completely new installation.
For example, where the base 105 may be attached to a top surface with nominal slope, the length of the stud 120 may not be a significant factor in the leveling of the railing system and additional length may add stability. Where the base 105 may be attached to a sloped surface, such as on subflooring sloped to help with drainage, the effective length of the stud 120 may be limited to allow for the leveling of the railing system.
In some embodiments, a concealed anchor system may be customized for a variety of deck variations, such as an open deck or decking involving wood, composite, aluminum, or vinyl materials. In some implementations, a concealed anchor system may be optimized depending on decking material, such as wood-thermoplastic composite materials, polyethylene, polypropylene, wood fibers, recycled plastic, PVC, polystyrene, stainless steel, Trex, Ipe, Meranti, Redwood, or pressure-treated lumber, as non-limiting examples. In some aspects, a post may be optimized depending on the decking material. In some embodiments, installation of a concealed anchor system on concrete may occur by drilling a threaded stud into a deck without using a base. In some implementations, a rail may be grouted for use in a pool.
In some embodiments, a concealed anchor system may have a receiver piece that slides over using a threaded rod. In some implementations, a concealed anchor system may have decorative features to complement a user's preferences. In some aspects, a post design may be used to mount to a wall for shelving. For example, a wall mount version may comprise two concealed anchor systems attached perpendicular to a wall, and a shelf may comprise openings that may be fitted onto the sleeves of the concealed anchor systems. In some embodiments, the base may be attached to the exterior of the wall. In some aspects, the base may be attached to studs, such as during construction before the installation of drywall. In some aspects, the concealed anchor system may be integrated into furniture. For example, legs of a table or couch may be fitted over the sleeve of a concealed anchor system, wherein the base may be attached to the seat portion or tabletop.
In some aspects, the concealed anchor system may be used in architectural features where it may be desirable to limit damage to the flooring or necessary to periodically change, repair, or remove the feature fitted over the concealed anchor system. For example, the concealed anchor system may be used to secure base features in an aquarium wherein the anchor system may maintain the sealed integrity of the aquarium and limit corrosion to the features. As another illustrative example, the concealed anchor system may be used to secure sculptural works at a museum, such as exterior statues or installation pieces that may be periodically rotated out.
In some implementations, a concealed anchor system may include different sleeves or different bases to use depending on user need. For example, where the railing post may comprise a cylindrical body, a square-shaped sleeve may not offer the most secure fit. In some embodiments, the sleeve may comprise a textured exterior, which may cause friction with the railing post and limit rotation of the railing post around the sleeve. In some aspects, the railing post may comprise an internal structure that may be fittingly secured over the sleeve that may not match the exterior. For example, the railing post may by cylindrical on the outside and have a square-shape internally that may fit over a square-shaped sleeve, wherein the square fitting may limit rotation of the railing post.
Referring now to
Referring now to
In some implementations, the series of holes may comprise the same or different shapes. For example, a larger hole may accept an end cap for the cable railing, whereas a smaller hole may allow for a cable pass-through. In some aspects, a corner railing may comprise two cable flanges 310 extending from perpendicular surfaces of the railing post, which may allow for a 90° turn in the railing system. In some embodiments, the angle between the cable flanges 310 may allow for a range of perimeter shapes.
In some aspects, the use of flanges eliminates the need for the cables to pass through the body of the railing post, which may expose portions of the railing post. The exposed portions may be susceptible to damage over time, which may weaken the components. For example, a drilled hole on the surface of the railing post may allow moisture to accumulate within the railing post, which may cause deterioration to the drilled hole, the interior of the railing post, the retainer cap, or other exposed components within the railing module.
In some embodiments, not shown, railing posts may comprise flanges that may accept other horizontal railing systems, such as rods, panels, or boards, as non-limiting examples. For example, the flanges may comprise a pocket configured to accept a panel that may extend to the next railing post. The panel may comprise one or more of a wood, plastic, glass, steel, or aluminum, as non-limiting examples. In some aspects, not shown, the railing system may comprise a series of vertical railings and the railing post may comprise flanges that may accept a base railing, wherein the panels, balusters, or rods may extend between the base railing and the upper railing. In some implementations, not shown, the railing post may comprise traditional railing designs utilizing the concealed anchor system as the means of attachment to a structure.
Referring now to
In some embodiments, the post base shoes 400, 410 may comprise an opening 405, 415 that may fit over the sleeve and under the railing post. In some aspects, the base shoes 400, 410 may be fitted with concealed securing mechanisms, maintaining a sleek exposed upper surface. For example, the post base shoes 400, 410 may be attached to the flooring surface with an adhesive. As another example, where a metal base may be exposed, the post base shoes 400, 410 may be magnetically connected to the base. In some aspects, the post base shoes 400, 410 may be allowed to float without being attached to a surface. In some implementations, a base shoe 400, 410 may distribute the point load of a railing once a nut is tightened on the retainer, which may limit compression of the railing post into the finished deck while adding rigidity to the rail post installation.
Referring now to
Referring now to
In some aspects, the corner retainer cap 600 may comprise a fitted portion 610 with a center hole 615 and a retainer base 630. In some embodiments, the fitted portion 610 may fit within the body of the railing post, wherein the center hole 615 may align with the threaded rod. The threaded rod may extend up to or through the center hole 615, which may allow for a nut to secure the corner retainer cap 600 to the railing module. In some aspects, railing may be secured to the retainer base 630, wherein the retainer base 630 may be parallel to the railing.
Referring now to
Referring now to
In some aspects, standard stairs 805 with standard angled railing system 800 may have a traditional aesthetic with sufficient space to extend the steps. In some embodiments, steep stairs 835 with steep angled railing system 830 may have a more modern aesthetic and may be appropriate where space is limited. In some implementations, a ramp 865 with moderate angled railing system 860 may allow for increased accessibility.
Referring now to
In some aspects, the leveler 900 may comprise adjustable legs 920 that may support the leveler 900, wherein each of the adjustable legs 920 may be independently adjusted. In some implementations, the adjustable legs 920 may comprise feet (not shown) that may add stability and limit damage to the flooring. For example, the feet may comprise a rubber or foam that may create a soft contact point with the flooring. As another example the feet may comprise a round base that may disperse any pressure to limit indentations that may be caused during the leveling process. In some embodiments, the leveler 900 may comprise a primary alignment mechanism 910, which may hold the sleeve of a railing module. The primary alignment mechanism 910 may comprise a sleeve, clamps, magnets, or other securing mechanisms, as non-limiting examples. In some embodiments, the primary alignment mechanism 910 may comprise a quick-release mechanism, such as a spring-loaded release mechanism, which may allow for easy alignment and installation.
In some aspects, the leveler 900 may comprise a secondary alignment mechanism 930, which may further secure the leveler 900 in alignment while the sleeve of a railing module is set to the stud. For example, the secondary alignment mechanism 930 may comprise a recess or flange with a hole that may accept a threaded rod connected to the stud or the stud itself. In some embodiments, the leveler 900 may comprise a bubble level 940 at the top of a stem 950. In some aspects, the length of the stem 950 may allow for a user to lean over to look down over the bubble level 940.
Referring now to
Accordingly,
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In some aspects, the guardrail module boot 1200 may comprise a guardrail post sleeve 1230 configured to accept a guardrail post. In some implementations, the guardrail module boot 1200 may comprise a lower support brace 1220 configured to accept an end of a base board, wherein a subsequent guardrail module boot may comprise another lower support brace to accept the other end of the base board. In some embodiments, the guardrail module boot 1200 may comprise an aperture 1225 and stability panels 1240 with drill holes 1215. The aperture 1225 may be configured to receive a stud 1205 from a concealed anchor system.
In some aspects, the stability panels 1240 may be drilled into a surface through the drill holes 1245, such as where flooring finishes have not been installed or partially installed or where damage to the surface may be easily repaired. In some embodiments, it may not be necessary or desirable to drill into the floor. For example, where the flooring may be partially installed, damage to the surface may not be easily repaired, so drilling into the flooring may cause unwanted damage. In some aspects, the stability panels 1240 may comprise non-skid material underneath to limit unintended slipping, wherein the non-skid material may comprise a material that may not damage the flooring, such as a rubber or silicone.
In some implementations, the guardrail post sleeve 1230 and guardrail module boot 1200 may be designed to allow for easy removal and re-installation of the upper portion of a guardrail post without the need to remove or unsecure the base. In some aspects, a retainer pin may be placed in the hole of the receiver with an aligned hole in the guardrail post. In some embodiments, this feature may provide better flexibility to a contractor and provide less wear on a deck.
Referring now to
At 1335, a threaded rod may be connected to the stud. At 1340, a railing post may be fitted over the sleeve. At 1345, a retainer cap may be placed in the railing post and threaded rod, and at 1350, the retainer cap may be secured, such as through use of a bolt or washer threaded over the threaded rod. At 1355, a railing may be attached to the retainer cap.
A number of embodiments of the present disclosure have been described. While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any disclosures or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the present disclosure.
Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in combination in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous.
Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
Thus, particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order show, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claimed disclosure.
