Patent Application
20230366236
The present disclosure relates to construction materials, and more particularly to a knock-down picket rail panel that is assemblable and disassemblable by a user or installer.
Rail panel systems generally are often installed by a professional contractor. They may be delivered to a job site fully assembled. Alternatively, rail panel systems may be delivered disassembled and the contractor may assemble the rail panel in connection with their installation. It is common for assembled rail panels to be cut to fit a particular length of a deck, platform or stairway on which the rail panels are installed. Fully assembled rail panels that are not easily disassembled and reassembled may be more difficult to be cut down to a size that fits a particular spacing between support posts. For example, the full rail panel will be supported during cutting down a welded rail panel to fit a spacing between support posts that is smaller than the length of the rail panel.
According to an embodiment, a rail panel can have a channel member having a bottom wall, the bottom wall defining a plurality of through holes that are configured to receive a picket, a pair of lateral side walls extend from the bottom wall, and a pair of locking walls extending inwardly from the pair of lateral side walls. The rail panel includes a picket with an end with an internal profile that is configured to receive the picket plug and an external profile configured to be received by the plurality of through holes. The rail panel may also have a picket plug having a first end configured to be received by the internal profile of the end of the picket and a second end configured such that the picket plug is secured within the channel member by the pair of locking walls in a first orientation and can be removed from the channel member in a second orientation.
According to another embodiment, a rail panel may be configured such that the picket plug is rotated 90 degrees from the first orientation to the second orientation.
According to yet another embodiment, a rail panel may be configured such that the picket also includes a threaded insert disposed within the picket that configured to receive a fastener.
According to other embodiments, a rail panel may be configured such that the picket plug is configured to receive the fastener.
According to another embodiment, a rail panel may also include a cover channel member configured to interface with the channel member.
According to other embodiments, a rail panel may be configured such that the picket plug also has at least one channel formed in the first end of the picket plug and the internal profile also has at least one inwardly extending wall, wherein the channel is configured to interface with the inwardly extending wall are.
According to another embodiment, a rail panel may also include a support member configured such that the support member is configured to be secured within the channel member by the pair of locking walls in a first orientation and can be removed from the channel member in a second orientation.
According to yet another embodiment, components of the rail panel including the top and bottom rails and the pickets are formed by extruding aluminum.
According to another embodiment, a method of assembling a knock-down rail panel from a kit may include the steps of providing a first and second channel. Each channel having a transverse wall, a pair of leg members extending from the transverse wall, and a pair of locking members extending inwardly from the pair of first leg members. The transverse wall defines a plurality of spaced apart through holes. Another step may be providing a picket. Wherein the picket is configured to be received by at least one of the spaced apart through holes. Another step may be providing a picket plug configured to interlock with the pair of locking members and couple to an end of the picket.
Technical advantages of the disclosed embodiments include a rail panel that may be shipped in packaging configured to contain a disassembled rail panel that is assemblable by the user/installer. The rail panel may include features to facilitate assembly that are formed during an extrusion process.
The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:
The drawings are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness.
Embodiments disclosed herein provide a system, an apparatus, and a method for a user assemblable rail panel system 100. In particular, embodiments disclosed herein provide a rail panel system 100 that can be easily assembled and disassembled. Thus, the user assemblable rail system 100 may be provided to a user either as an assembled panel or in discrete components. In installing the rail panel 100 on a deck of a user, the rail panel may be easily disassembled and reassembled to allow for cutting down the panel to fit a particular spacing between posts. The selection and mix of different components, the ratio of standard pickets 16 to support pickets 14 can be made to fit the application needs or preferences of the end user.
Referring to
In some embodiments, the user assemblable rail panel 100 can be installed between a pair of posts 13 disposed at each end of the rail panel 100. Alternatively, the rail panel 100 may be supported at one or both ends by a structure such as an outside wall of a home. Brackets 11 may be secured to a face of one of the posts 13 in positions to support the top rail 10 and the bottom rail 12, as shown. The brackets 11 may be U-shaped such that the top rail 10 and the bottom rail 12 is supported by a bottom wall of the U-shaped bracket and fasteners may be received through either one or both of the side walls to secure the top rail 10 and the bottom rail 12 to the bracket 11. Fasteners may be received through the back wall of the bracket and into the post 13 to secure the bracket 11 to the post 13.
The embodiment shown in
The infill of the rail panel 100 may include any suitable number of support pickets 14 and standard pickets 16. For example, the rail panel 100 shown in
A rail panel 100 with less than three or more than three support pickets 14 is contemplated by this disclosure. For example, the user assemblable rail panel 100 may include an infill of only support pickets 14 (e.g. twenty) without the use of standard pickets 16. The rail panel system 100 can be manufactured in any suitable length. For example, the rail panel system 100 may be manufactured in approximately six foot or eight foot lengths.
Referring now to
Each of the top rail member 10 and the bottom rail member 12 includes a transverse wall 30, a pair of side walls 32 extending from the transverse wall 30, and a pair of locking ledges 36 extending inwardly from each of the side walls 32. In this embodiment, the transverse wall 30 also includes a plurality of clearance openings 40 through the transverse wall 30. The clearance openings 40 are spaced apart along the length of the transverse wall 30. Each clearance opening is configured to receive a portion of a picket plug, for example the top picket plug 18 or the bottom picket plug 20.
Each of the top rail 10 and the bottom rail 12 can be manufactured using metallic materials including, but not limited to, aluminum, iron, carbon steel, or stainless steel. In other embodiments, the rail members 10, 12 can be manufactured using an extrudable composite material that includes a wood-type filler. According to another embodiment, the rail members 10, 12 can be manufactured using plastic materials including, but not limited to, Acrylic or Polymethyl Methacrylate (“PMMA”), Polycarbonate (“PC”), Polyethylene (“PE”), Polypropylene (“PP”), Polyethylene Terephthalate (“PET”), Polyvinyl Chloride (“PVC”), or Acrylonitrile-Butadiene-Styrene (“ABS”).
According to an embodiment, the standard picket 16, support picket 14, top rail member 10, bottom rail member 12, and rail cap 24, are all aluminum extrusions. Aluminum extrusions form a strong, durable, yet light weight rail panel system 100.
Referring now to
Alternatively, the inner profile 48 may be omitted, for example if the rail cap 24 is assembled to the bottom rail 12, which is less likely to receive a sudden lateral force. In this embodiment, the rail cap 24 is used as a covering for the open or exposed channel 17 of the top rail 10.
The inner profile 48 of a rail cap 24 can have a square, rectangular, circular, oval, hexagonal, octagonal, or any other profile such that the rail cap 24 can interface with a top or bottom rail 10, 12. The inner profile 48 of the rail cap 24 can add structural rigidity to the rail cap 24. In some embodiments the rail cap 24 may not have an inner profile 48.
In various embodiments, the rail cap 24 is made of like material as the rail member 10, that it can be affixed to, such as extruded aluminum. In other embodiments, the rail cap 24 is made of a material that is different from the material of the rail member 10 to which it is secured. For example, the top rail member 10 may be formed of extruded aluminum and the rail cap 24 may be formed from an extruded polymeric material.
In other embodiments, a rail cap 24 is secured to both the top rail member 10 and the bottom rail member 12. In other embodiments, a single rail cap 24 is secured to either the top rail member 10 or the bottom rail member 12, for example the top rail member 10.
According to the embodiment illustrated by
Reference is now made to
The support picket 14 adds rigidity and strength to the rail panel 100. The cross sectional view of support picket 14 illustrated in
The threaded member 28 also includes a transverse through hole 35 that is sized to receive a pin to secure the threaded member 28 at a predetermined depth within the support picket 14. When the threaded member 28 is positioned in the support picket 14, the through hole 35 is aligned with a hole 15 in one or more of the walls of the support picket 14. The through hole 35 is aligned with the through hole 15 to receive a pin to secure the threaded member 28 at the proper depth within the support picket 14. The depth of the threaded insert 28 may be selected to allow the insertable portion of the picket plug 20 to be received between the threaded insert 28 and the end of the support picket 14. The pin (not shown) may be welded, ground and powder coated, such that the welded pin does not show in the finished support picket 14. Alternatively, the transverse through hole 35 may be omitted and the threaded insert/member 28 may be welded in position through the through hole 35.
The threaded member 28 allows the support picket 14 to receive fasteners 22 to secure the support picket 14 to the top rail 10 and the bottom rail 12. In this manner, the support picket 14 adds rigidity and strength to the panel 100. As discussed in further detail below, the support picket 14 receives a portion of the picket plug 20 and also the fastener 22 that extends through the picket plug 20 and is received in threaded engagement with the female threads 29 of the threaded insert 28. The support picket 14 serves to secure the top rail 10 to the bottom rail 12 and thereby hold the panel together and secure the standard pickets 16 in position as the infill of the rail panel 100. In some embodiments, only a single support picket 14 is used with the rail panel system 100 while in other embodiments a plurality of support pickets 14, for example three support pickets 14 are positioned nearest each of the pair of support posts and at a midpoint of the rail panel 100.
Reference is now made to
In some embodiments, the standard picket 16 or support picket 14 can be made of such material to allow for the junction of the end of the picket 16, 14 and the picket-insertable portion of the picket plug 20 to have an interference fit. In other embodiments, the junction of the standard picket 16 or support picket 14 with the picket plug 20 may also be a cantilever snap-fit joint, an annular snap-fit joint, a torsional snap-fit joint, or any other assembly technique that minimizes the amount of excess tools that a user may be required to have available.
To make fabrication efficient, the standard picket 16 and the support picket 14 may be extruded to have the same profile and cut to length. The support picket 14 may be the same as the standard picket 16 with the exception of not including the threaded insert 28 or the through hole 15. The common profiles of the standard picket 16 and the support picket 14 allows a common picket plug 20 to be used for both picket types. Alternatively, the support picket end profile may be different from the standard picket end profile.
In some embodiments, a standard picket 16 is made of the same material as the rail member 10. In yet another embodiment, the standard picket 16 is made of the same material as the support picket 14, whereas in others, they are made of different materials or different types of materials.
Reference is now made to
In this embodiment, the bottom picket plug 20 includes a pair of locking lugs 60. The locking lugs 60 extend from a body of the picket plug 20 such that when the picket plug 20 is in the free or insertable orientation, the picket plug 20 may be inserted into or removed from a rail member 10, 12. Once inserted into the rail 10, the picket plug 20 can be rotated a quarter turn to the locked orientation, such that the picket plug 20 is secured within the rail member 10, 12 in that the locking lugs 60 are positioned between the locking ledges 36 and the transverse wall 30 within the open channel 17. Once rotated into the locked orientation, the locking lugs 60 engage or interlock with the locking ledges 36, to secure the picket plug 20 to the rail member 10.
In the present embodiment, the keyed access feature 62 is illustrated such to accept a male hex shaped tool. However, the keyed access feature 62 is capable of being any kind of structure that enables a user to rotate the top picket plug 18 within the rail 10, preferably with a tool. Such structures include but are not limited to a male hex bolt head, a slot or pair of slots for a flathead or Philips head screwdriver, a cube shaped hole or lug, a star shaped hole or lug, or any other type of head that can be utilized with a tool that facilitates the quarter turn rotation of the picket plug 20.
In the present embodiment, the keyed access feature 62 also corresponds to a through hole 65 to receive a fastener when the picket plug 20 is used to secure a support picket to the top rail or the bottom rail 12. The purpose of through hole 65 is such that the fastener 22 utilized for the support picket 14 can be received through the picket plug 20. In certain embodiments, the through hole 65 may be advantageously collocated with the keyed access feature 62. The through hole may be countersunk to allow the head of the fastener 22 to sit substantially flush with the top surface of the picket plug 20. Also, the same picket plug 20 may be used with either a standard picket 16 or a support picket 14, depending on whether the particular picket plug 20 also receives a fastener through the through hole 65. In other embodiments, the keyed access feature 62 may be a blind hole, a countersunk hole, a counter-bored hole, or any other type of hole or recess that would allow for the keyed access feature 62 to operate to rotate the picket plug one quarter turn to lock it to the top rail or the bottom rail, as previously described.
In some embodiments, some components are identical between the top and bottom picket plug 18, 20, such that there is no difference between the top picket plug 18 and the bottom picket plug 20. In another embodiment, the differences are such that the top picket plug 18 and the bottom picket plug 20 are not interchangeable at all. Such differences may include the bottom picket plug being thicker than the top picket plug 18.
Reference is now made to
In the illustrated embodiment, portions of the standard picket 16 and the support picket 14 are received in their respective clearance openings 40. The clearance openings 40, the pickets 14, 16, and the picket-insertable portions 68 of the picket plugs 20 are sized and shaped such that a clearance is formed around the picket-insertable portion 68 of the picket plug 20 and the walls of the opening 40. Alternatively, the sizes of the opening 40 and the picket (support picket 14 or the standard picket 16) may be such that the picket 14, 16 is not received in the opening 40, and therefore is outside of the bottom rail 12. In this embodiment, each end of the standard picket 16 and the support picket 14 bear on the top rail 10 and the bottom rail 12, as opposed to the top and bottom picket plugs 18, 20.
Reference is now made to
Referring now to
Referring now to
Reference is now made to
According to an alternate embodiment, the tabs are not received in holes or depressions in the picket, but rather create an interference fit to hold the standard picket 16 in place. The embodiment shown in
A method of assembly of a rail panel 100 begins in some embodiments with first inserting the picket plugs 20 into their position in the bottom rail 12 in the free orientation. Then aligning the picket plugs 20 with the plurality of spaced apart clearance openings 40. Then, rotating the picket plugs 20 into the locked orientation. Next, fitting the support pickets 14 over their designated picket plugs 20 by inserting the support picket 14 through their respective spaced apart clearance openings 40 and aligning the inwardly extending walls 53 of the picket with the channels 63 of the picket plugs 20. Subsequently, the fastener 22 is installed through the picket plug 20 and threaded it into the insert 28. Next, the standard pickets 16 are fit over the remaining picket plugs by inserting the standard pickets 16 through their respective spaced apart clearance openings aligning the inwardly extending walls 53 of the pickets with the channels 63 of the picket plugs 20.
Afterwards, the picket plugs 18 are installed in the top rail 10 first by inserting them into rail 10 in the free orientation, aligning them with the plurality of spaced apart clearance openings 40, then rotating the into the locked orientation. The top rail 10 is then aligned with the bottom rail 12, such that the picket plugs 18 of the top rail are aligned with the respective standard pickets 16 and support pickets 14. The top rail 10 is then moved down such that the standard pickets 16 and support pickets 14 interface with the picket plugs 18 such that the channels 63 of the picket plugs 18 engage with the inwardly extending walls 53 of the pickets. The fastener 22 is then inserted through the picket plugs 18 associated with the support pickets 14, and then threaded into the insert 28. The rail cap 24 is then slid over the top rail 10 such that the picket plugs 18 are concealed.
Although embodiments of the rail panel system 100 have been described in detail, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.
According to an embodiment, the user assemblable rail panel 100 may be provide as a knock-down panel. In this embodiment, the installer may receive a kit or box with unassembled components. The unassembled components may be easier to ship and store than an assembled rail panel 100. The knock-down user assemblable rail panel 100 may be shipped with the top rail 10, support pickets 14, standard pickets 16, and the bottom rail 12 separate from each other. The top picket plugs 18 may be installed in the top rail 10 and the bottom picket plugs 20 may be installed in the bottom rail 12 or they too may be shipped separate.
In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “left” and right”, “front” and “rear”, “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.
In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.
In addition, the foregoing describes some embodiments of the disclosure, and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.
Furthermore, the disclosure is not to be limited to the illustrated implementations, but to the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the disclosure. Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.
