ROD RAILING AND METHOD OF INSTALLATION

Abstract

A method of assembling and installing a rod infill deck railing system utilizing baluster and baluster connection apparatuses is disclosed in which rods are inserted through sound-dampening balusters, which are connected to upper and lower rails by a pressure coupling structure. The rod infill deck railing system largely eliminates rod rattling found in other rod railing systems, is easily adaptable for use on steps, and can be assembled into components before their attachment to posts.

Description

FIELD OF THE INVENTION

The present disclosure is generally directed to railing systems, particularly those rod railing systems used in residential and commercial settings to prevent falls from an elevated surface such as a deck or stairs.

BACKGROUND OF THE INVENTION

Many building codes require that decks and associated stairs have sturdy railings to prevent accidental falls.

Cable railing is often chosen for this application because of its strength, cost, and aesthetics. However, rod infill railing is an attractive alternative. As the name suggests, rod infill railing uses rods instead of cables. Solid rods have certain advantages, such as there being no possibility of cables loosening over time or under-tightened cables becoming a hazard. There is also no possibility of over-tightened cables causing undue stress on the railing system's rails and balusters. Since there is no need to tighten cables, installation generally requires fewer steps, and less time is needed to install rod infill railing.

Rod infill railing is made with round metal rods, which leave no point of weakness or cavitation that could promote corrosion or rust, making rod infill railing preferable in many outdoor installations, particularly those exposed to particularly corrosive conditions. Rod railing not only provides an attractive border highlight but also provides the barrier strength needed to prevent someone at a cookout from falling off a raised platform or deck while reaching for another hot dog and to prevent someone in line for a roller coaster from falling off the steps leading to the platform. Additionally, the strength and stability of rod infill railing is highly desired in hazardous situations such as pedestrian bridges or skyways, or for creating a safety barrier in industrial sites.

Many rod infill railing installations are suitable for a weekend DIY project, however existing designs and installation techniques may be outside of the purview of many. Any slight movement that would cause a rod to tap a hollow metal baluster can turn the railing into a cacophonous collection of untuned bells. What is needed is a rod infill railing system that simplifies installation and provides a clean, aesthetic final appearance and reduces or eliminates the noise associated with some rod infill railing installations.

Other features and advantages will be made apparent from the present specification. The teachings disclosed extend to those embodiments that fall within the scope of the claims, regardless of whether they accomplish one or more of the needs mentioned above.

SUMMARY OF THE INVENTION

A rod infill railing system that addresses these needs is disclosed here.

One unique aspect of the rod infill railing system is that it is modular, and sections of railing may be assembled separately prior to being attached to posts. This modular design allows for the railing to be assembled and installed in discrete steps. For example, one could assemble the individual railing sections first, then move to installing the posts and connecting the sections. This allows an installer to complete one aspect of the project at a time, increasing efficiency and assembly speed. Alternatively, assembling the rod infill railing sections, attaching the sections to the posts, and fixing the posts to a surface could be divided amongst installers.

Another feature of the disclosed rod railing system is that, when installed on stairs, the internal balusters of each section of rod infill railing are vertical to the mounting surface when the rods themselves are at an angle.

Yet another feature of the rod infill railing is the methods and components that stabilize the rods also muffle unintended rattling.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates a segment of the rod infill railing connected to two vertical posts.

FIG. 2 shows a side view of a level baluster mount.

FIG. 3 shows an orthogonal view of a level baluster mount.

FIG. 4 shows a side view of an angled baluster mount.

FIG. 5 shows an orthogonal view of an angled baluster mount.

FIG. 6 shows a spring clip from the front side.

FIG. 7 is an illustration of a rod, including a break line.

FIG. 8 is an illustration of a baluster, including a break line.

FIG. 9 illustrates a sound-dampening insert for a baluster, including a break line.

FIG. 10 illustrates a portion of a baluster with a pair of sound-dampening inserts, including a break line.

FIG. 11 illustrates a bottom rail showing the placement of baluster mounts and spring clips.

FIG. 12 is an illustration showing the placement of two balusters onto the bottom rail.

FIG. 13 illustrates the insertion of a pair of sound-dampening inserts into a baluster.

FIG. 14 illustrates the insertion of several rods into two balusters.

FIG. 15 is a view from the top of a baluster illustrating how an inserted rod presses against the sound-dampening inserts.

FIG. 16 illustrates the addition of a second-end baluster onto the bottom rail and it is pressed toward the internal baluster to secure the second ends of the rods.

FIG. 17 illustrates a top rail being placed onto three balusters.

FIG. 18 illustrates the connection of a vertical post to a platform.

The same reference numbers will be used throughout the drawings to represent the same parts wherever possible.

DETAILED DESCRIPTION OF THE INVENTION

Each reference number consists of three digits. The first digit corresponds to the figure number in which the referenced item is first or best shown. Reference numbers are not necessarily discussed in the order of their appearance in the figures. Drawings are not necessarily to scale. As used herein, “has” and “have” are synonymous with “comprising.” Although a “post” is described as a free-standing vertical structure, the term should be understood to include all similar structural members. Further, although cables are most commonly understood within the scope of this disclosure as a rope of metallic fibers, a cable may refer to similar structures of non-metallic materials and non-rope structures, such as, e.g., wires or dowels having the same general shape or function.

For ease in drafting, and hopefully also of reading, aspects of the subject matter of this application are described in terms of a single segment of railing between two posts; however, the teachings of this disclosure apply to and are most commonly used with multiple railing segments. Also, for ease of drafting and hopefully reading, the procedure for preparing a railing segment and attaching it to a set of posts is described once. However, in practice, most cable railings will comprise several such segments.

While the embodiments illustrated in the figures and described herein are presently preferred, these embodiments are just examples. Those skilled in the relevant arts may appreciate modifications that could be made but do not materially depart from the teaching of this disclosure. The subject matter of this application is not limited to a particular embodiment but extends to various modifications that nevertheless fall within the scope of the claims. The order or sequence of any processes or method steps may be varied or re-sequenced according to alternative embodiments. For example, elements shown as integrally formed may be constructed of multiple parts or components, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present application. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the scope of the present application.

A method of assembling a rod railing infill segment for a deck railing comprises providing a first vertical support post (101) and a second vertical support post (102). Each said vertical support post is comprised of an elongated member having an inward-facing side (e.g., 103), an outward-facing side (e.g., 104), a top (e.g., 105), a bottom (e.g., 106), and a longitudinal axis (e.g., 107). The bottom of each elongated member also comprises a base support flange (1801) comprising several mounting holes (e.g., 1802). Further provided is a leveling plate (1803). Once so provided, each bottom of a vertical support post is positioned on a mounting surface, such as a deck, and a leveling plate is placed between the rail support post and the mounting surface. Holes (1804) are drilled through the mounting holes of each support flange into the mounting surface, and the rail support posts are fixed into place with suitable mounting hardware (e.g., 1805).

The assembly method also provides a top rail (1701) and a bottom rail (1201). Said top rail has a first end (1702), a second end (1703), a top (1704), a bottom (1705), and a longitudinal axis (1706) perpendicular to the longitudinal axis of the vertical rail support posts. Said bottom rail (1201) also has a first end (1202), a second end (1203), a top (1204), a bottom (1205), and a longitudinal axis (1206) perpendicular to the longitudinal axis of the mounted rail support posts.

The bottom of the top rail (1705) comprises a number of baluster mount attachment points (e.g., 1101). The top of the bottom rail (1204) also comprises baluster mount attachment points. Each top rail baluster mount attachment point is paired with a bottom rail baluster mount attachment point.

The assembly method further provides a baluster mount (e.g., 301, see also FIGS. 2-3, 4-5) located at each baluster mount attachment point. In a most highly preferred embodiment, each baluster mount is attached to a baluster mount attachment point with a screw. In other embodiments, baluster mounts may attach in another way, such as with clips, or may be formed in situ as part of the rail itself. In preferred embodiments each baluster mount comprises a base (201), a pair of invaginations or “pinches” as seen from the side (202a. 202b) and a bulbous top portion (203), The baluster mounts are capped with a spring clip (e.g., 601), which has a bulbous top (602) and two ends (603a, 603b) which fits over the bulbous top portion of the baluster mounts and the two ends of the spring clip fit within the pair of invaginations.

In a most highly preferred embodiment, the position of each baluster mount attachment point is marked and drilled as needed, allowing for flexibility in the total length of the top and bottom rails. In such embodiments, a guide or chuck may be provided to ensure proper spacing. In other embodiments, the baluster mount attachment points are provided with suitably spaced pre-drilled holes.

The assembly method further provides a number of balusters (e.g., 1208). Each said baluster having a longitudinal axis (1209), a top end (1210), a bottom end (1211), an internal space (801), and a plurality of side holes (e.g., 1212) adapted to allow the insertion of a rod so that the inserted rod is parallel to the bottom and top rails.

The top end and the bottom end of each baluster comprise a gap or invagination (802) having a size and shape complementary to that of a baluster mount capped with a spring clip such that pressing a baluster onto a spring clip-capped baluster causes the deflection of the spring clip securing the baluster to the baluster mount.

The assembly method further provides sound-dampening inserts (901) sized to fit within a baluster. Said sound-dampening inserts have a longitudinal axis (1301), a bottom (1302), a top (1303), an inward side (1001), and an outward side (1002). In most preferred embodiments, the inserts are placed within the baluster in pairs such that each inward side is opposite to and facing the inward side of the other insert (FIGS. 10, 13). Each insert is curved inward and capable of being deflected by an object, such as a rail inserted through one of the baluster side holes.

The assembly method also provides a number of rods (e.g., 1401) comprising a first end (1402), a second end (1403), and a longitudinal axis (1404).

To assemble a section of railing according to the teachings of this specification, a bottom rail is placed on a surface such that the bottom is against said surface. Baluster mounts are installed as needed to the baluster mount attachment points located on the bottom rail. Spring clips are then pressed onto the baluster mounts.

A further assembly step discusses a section of railing having three balusters. A first-end baluster (1707), a second-end baluster (1708), and an internal baluster (1709). A three-baluster design is preferred, and it is used as an example of railing for ease in drafting. Other designs may have more internal balusters. End balusters most typically have side holes only on one side of the baluster, as can be seen in the illustrations. The center or internal balusters have side holes on two sides to allow a rod to be pressed through said balusters.

A first-end baluster is oriented such that the side holes face the center of the section of the railing and are pressed onto a baluster mount located near the first end of the bottom railing, locking the first-end baluster into place (FIG. 12).

An internal baluster is oriented such that one set of the internal baluster's side holes faces the first-end baluster's side holes and is pressed onto an internal baluster mount on the bottom railing, locking the internal baluster into place (FIG. 12).

Sound-dampening inserts are placed within the first end and internal balusters (FIG. 13).

The first end of a rod is slid through a pair of side holes of the internal baluster and is ultimately pressed into a side hole of the first end baluster so that the rod is parallel to the bottom rail (FIG. 14). This is repeated until each set of side holes contains a rod. In this manner, each rod is held within each baluster between a pair of sound-dampening inserts (FIG. 15).

The second-end baluster is angled slightly away from the second end of the rods and pressed onto an internal baluster mount and associated spring clip. A pair of sound-dampening inserts are inserted into the second-end baluster.

The second-end baluster is straightened to be perpendicular to the bottom rail, while the second-end of each rod is inserted into the corresponding side hole of the second-end baluster (FIG. 16).

The top rail is positioned over the first-end, second-end, and internal balusters and pressed down such that the baluster mounts and associated spring clips located on the bottom of the top rail are inserted into said balusters (FIG. 17).

The assembled section is then attached to the first vertical support post and the second vertical support post.

An angled bluster mount (FIGS. 4, 5) may be provided for use on stairs or other inclines. Such an angled baluster mount allows bottom and top rails to be parallel to the stairs, while the end and internal balusters are transverse to the stairs and approximately parallel to the balusters and support posts located on the mounting surface.

Claims

1. A baluster comprising a length, a longitudinal axis, an outside surface, an inside surface, a front, a first insert, a rear, a first side, and a second side; said first side comprising at least one hole, adapted to allow the insertion of a rod into said hole;said inside surface of the baluster defining a longitudinal channel having a center;said baluster further comprises a first strip of flexible material within said channel;said first strip of flexible material forming an arc;said arc being perpendicular to the longitudinal axis of the baluster;said arc comprising a first terminus, a second terminus and an apex, in which the first terminus and the second terminus are in contact with the inside surface of the baluster.The baluster of claim 1 further comprising a second strip of flexible material within the channel;said second strip of flexible material forming an arc;said arc being perpendicular to the longitudinal axis of the baluster;said arc comprising a first terminus, a second terminus and an apex, in which the first terminus and the second terminus are in contact with the inside surface of the baluster;the apex of the arc formed by the first strip of flexible material being proximal to the apex of the arc formed by the first strip of flexible material; andeach said arc being located proximal to the center of the channel of the baluster.The baluster of claim 2 in which each said flexible strip has a length less than or equal to the length of the baluster.A segment of rod infill railing comprising a rail and a baluster mount having a bottom portion, a rail connection point, and a top;said bottom portion of the baluster mount configured to be in contact with the rail,said rail connection point of bottom portion of the baluster mount being adapted to connect to the rail;said top of the baluster mount being adapted to fit within a baluster and secure itself to the baluster.A baluster mount adapted for connecting a rail to a baluster, said baluster mount comprising a bottom, a top, and a longitudinal axis,said baluster mount comprising an internal surface defining a channel,said bottom comprising a planar surface, andsaid top comprising an apex transverse to the planar surface of the bottom of the baluster mount,said bottom surface adapted to attach to a bottom rail; andsaid top being adapted to at least partially fit within the channel of said baluster, creating a pressure fit between the apex of the baluster mount and the internal surface of the baluster.The baluster mount of claim 5 in which said longitudinal axis is perpendicular to the plane of the bottom surface.The baluster mount of claim 5 in which said longitudinal axis is transverse to the plane of the bottom surface.The baluster mount of claim 5 in which said top further comprises a spring clip adapted to apply internal pressure to the baluster.A method of assembling a section of rod infill railing comprising the steps of:providing a first post and a second post, each said post having an inward side and an outward side;providing a top rail comprising a longitudinal axis, a length, a first end, a second end, a top, a bottom comprising a plurality of holes, one or more baluster mounting points, and an internal space; andproviding a bottom rail comprising a longitudinal axis, length, a first end, a second end, a top comprising a plurality of holes, one or more baluster mounting points, a bottom, and an internal space; andproviding a plurality of balusters, each comprising a first side, a second side, an inner channel, a longitudinal axis, and at least one hole in one or more sides;providing a number of baluster mounts;providing at least one rod having a longitudinal axis, a first end, a second end, a length, and being adapted to fit within at least one said hole of a baluster;providing at least one insert adapted for placement within a baluster;securing the first and second posts to a surface, so that the inner side of the first post faces the inner side of the second post, and the space between the two said inner sides is equal to the length of the bottom rail; andassembling a unit of rod railing comprising the steps of:placing a baluster onto a baluster mount located on said bottom rail, said baluster mount being adapted to press against the inner channel of said baluster; repeating with each desired baluster in a series, such that each series of balusters is comprised of a first baluster and a second baluster;placing a first and a second insert into the internal channel of each placed baluster such that each said insert comprises defines an arc being perpendicular to the associated baluster and having an apex, each arc being a mirror image of the other, and each apex being proximal to the other;inserting one or more rods through the holes of the placed balusters such that each rod is parallel to the bottom rail and the first end of each rod is contained within the inner channel of the first baluster and the second end of each rod is contained within the inner channel of the second baluster;placing a top rail comprising one or more baluster mounts onto the top of the series of balusters such that each baluster contains a baluster mount associated with the top rail, each said baluster mount being adapted to press against the inner channel of the associated baluster; andconnecting the assembled unit of rod railing to the inward side of the first post and the inward side of the second post.The method of claim 9 further comprising a number of baluster clips, each said baluster clip placed on a baluster mount prior to the placement of a baluster onto said mount.The method of claim 9 in which said series of baluster further comprises at least one intermediate baluster, between the first and second balusters.The method of claim 11 in which each said rod is inserted into the first baluster and each intermediate baluster before the second baluster is placed onto the positioned baluster mount and positioned to accept the second end of each said rod.