PRIORITY CLAIM

[1] This application claims priority to United States Provisional Application for Patent No. 61/979,083 filed April 14, 2014, the disclosure of which is incorporated by reference.

BACKGROUND OF THE INVENTION

Technical Field of the Invention

[2] The present invention relates generally to barriers (such as railings or fences) and in particular to a barrier panel utilizing cables as horizontal barrier members.

Description of Related Art

[3] It is common to form a barrier for railing or fence applications made, for example, of a plurality of panel members, with each panel member supported between and attached to a pair of post members. Each panel generally comprises a bottom rail extending between two posts and a top rail also extending between those same two posts. A plurality of vertical support members (also referred to in the art as pickets or balusters) extend between the bottom rail and the top rail. The bottom rail, top rail and vertical support members are made of a metal material (such as steel or aluminum). In an embodiment, first ends of the vertical support members are fixedly attached to the bottom rail (for example, through brackets or welding) and second ends of the vertical support members are fixedly attached to the top rail (again, for example, through brackets or welding).

[4] The panel may be pre-assembled before delivery to a job site. In such a case, the installer may simply install the pair of posts with a separation substantially equal to a length of the panel. The installed posts should have an exposed height that is greater than a height of the panel. Brackets mounted on each post accept and retain ends of the bottom and top rails.

SUMMARY

[5] In an embodiment, an apparatus comprises: a first vertical rail member including a plurality of first openings spaced apart along a length of the first vertical rail member; a second vertical rail member including a plurality of second openings spaced apart along a length of the second vertical rail member; a top rail member; a bottom rail member; wherein the first and second vertical rail members are mounted to and extend between the top and bottom rail members; and a plurality of cables mounted to and extending between the first vertical rail member and second vertical rail member, wherein a first end of each cable is secured within one of the first openings and a second end of each cable is secured within an opposite one of the second openings.

[6] In an embodiment, an apparatus comprises: a rail member including: an outer U-shaped channel; and an inner U-shaped channel; wherein said inner U-shaped channel is mounted within the outer U-shaped channel with open ends of the inner and outer U-shaped channels facing each other; inner openings spaced apart along the length of the inner U- shaped channel; and outer openings spaced apart along the length of the outer U-shaped channel; wherein each inner opening is aligned with a corresponding outer opening; and a plurality of cables mounted to said rail member, wherein an end of each cable is secured within aligned inner and outer openings.

BRIEF DESCRIPTION OF THE DRAWINGS

[7] A more complete understanding of the method and apparatus of the present invention may be acquired by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein: [8] Figure 1 is a front view of an embodiment of a cable rail panel;

[9] Figure 2 is a perspective view of a bottom rail and top rail;

[10] Figure 3 is an end view of the bottom rail and top rail;

[1 1] Figure 4 is a perspective view of a vertical support member;

[12] Figure 5 illustrates details of the assembly of vertical support members to bottom/top rails;

[13] Figures 6A-6B and 8 are perspective views of a vertical rail;

[14] Figure 7 is a cross-sectional view of the vertical rail;

[15] Figure 9 illustrates details of the assembly of a vertical rail to a top/bottom rail;

[ 16] Figure 10 is a perspective view of a cover plate;

[17] Figures 11A and 11C are exploded perspective views of clamping systems to engage a first end of a cable;

[18] Figure 11B is an assembled cross-sectional view of the clamping system of Figure 11 A;

[19] Figure 11D is an exploded cross-sectional view of the clamping system of Figure 1 1C;

[20] Figure 1 IE is a perspective view of a fitting at a second end of the cable;

[21] Figures 11F-11G are views of an alternative embodiment for a clamping system;

[22] Figure 12A is an end view of a vertical rail with an installed clamp fitting;

[23] Figure 12B is a perspective view of the installed clamp fitting;

[24] Figure 13 A is an end view of a vertical rail with an installed adjustable fitting;

[25] Figure 13B is a perspective view of the installed adjustable fitting; [26] Figure 14 illustrates an end view of a cap member;

[27] Figure 15 illustrates installation of the cap member;

[28] Figure 16 illustrates an alternative cap member; and

[29] Figures 17A-17G illustrate an implementation of the cable rail panel useful in a stair or sloped installation.

DETAILED DESCRIPTION

[30] Reference is now made to Figure 1 which illustrates a front view of an embodiment of a cable rail panel 10 (configured to be installed between two post members 8). The panel 10 includes a bottom rail 12 and a top rail 14 that are spaced apart from each other by vertical members. The vertical members include a pair of vertical support members 16 (extending between the bottom and top rails) and a pair of vertical rails 18 (extending between the bottom and top rails). The vertical members are spaced apart from each other along the lengths of the bottom and top rails. In particular, the vertical support members 16 are positioned at locations between the ends of the rails 12 and 14 while the vertical rails 18 are positioned at or near the ends of the rails 12 and 14. The bottom rail 12, top rail 14, vertical support members 16 and vertical rails 18 are made of a metal material (such as steel or aluminum). First ends of the vertical support members 16 and vertical rails 18 are fixedly attached (for example, by welding, bolts or brackets) to the bottom rail 12. Second ends of the vertical support members 16 and vertical rails 18 are fixedly attached (also, for example, by welding, bolts or brackets) to the top rail 14. The panel 10 further includes a plurality of horizontal cables 20 spaced apart from each other along the lengths of the vertical support members 16 and vertical rails 18 and extending between the vertical rails 18. The means for cable attachment will be discussed in more detail herein. Each end of the bottom and top rails is configured for attachment to the post member 8, for example, through the use of a bracket mechanism as known in the art.

[31] Reference is now made to Figure 2 which illustrates a perspective view of the bottom rail 12 and top rail 14 and further to Figure 3 which illustrates an end view of the bottom rail 12 and top rail 14. The rails 12 and 14 are formed of a U-shaped channel member 22. Each channel member 22 is formed of a web member and an opposed pair of leg members extending generally perpendicularly from the web member. The space between the leg members defines the open end of the channel member 22. The web member includes a plurality of openings 24 spaced apart along the length of the channel member 22. When assembled to form the panel 10 (see, Figure 1), the open end of the channel member 22 for the bottom rail 12 faces down and the open end of the channel member 22 for the top rail 14 faces up. The ends of the rails 12 and 14 and mounted to the post members 8 using the bracket mechanism.

[32] Reference is now made to Figure 4 which illustrates a perspective view of the vertical support member 16. In a preferred embodiment, the vertical support member 16 is a solid bar member 26 having a desired cross-section including, for example, square, rectangular, circular, hexagonal, octagonal, or the like. A plurality of openings 28 are provided along the length of the member 16 to pass through the bar member 26. Each end of the bar member 26 includes a threaded opening 30.

[33] In an alternative embodiment, the members 16 are hollow tubular members having a desired cross-section including, for example, square, rectangular, circular, hexagonal, octagonal, or the like. Such a tubular member may include a threaded opening similar to that shown in Figure 4 at each end. [34] Reference is now made to Figure 5 which illustrates details of the assembly of the vertical support members 16 to the rails 12 and 14. At selected correspondingly positioned ones of the openings 24 along the length of the rails 12 and 14, attachment is made to opposed ends of each vertical support member 16. Mounting hardware 32 is used to make the attachment. The mounting hardware 32 may, for example, comprise a bolt, screw or other threaded connector as known in the art with the threaded shaft of the hardware extending through the opening 24 in the rail web to engage the threaded opening 30 provided in the vertical support member 16. The openings 28 are oriented to extend in the plane of the panel 10 to permit passage of the cables 20 therethrough.

[35] Reference is now made to Figures 6A and 6B which illustrate perspective views of the vertical rail 18 and further to Figure 7 which illustrates a cross-sectional view of the vertical rail 18. The vertical rail 18 is formed of a first U-shaped channel member 40 and a second U-shaped channel member 42. The channel members 40 and 42 are made of a metal material, such steel or aluminum, and are fixedly attached to each other (for example, by welding) with the first channel member 40 fitting within the second channel member 42 and the open ends of the two channel members oriented facing each other. The welded attachment may, for example, comprise welding edges or surfaces of the channel member 40 to inner surfaces of the channel member 42. Spot or resistance welding techniques may be used in a manner well known to those skilled in the art. In a preferred implementation, evidence of the welding would not be visible on an outer surface of the channel member 42.

[36] Each channel member 40 and 42 is formed of a web member and an opposed pair of leg members extending generally perpendicularly from the web member. The space between the leg members defines the open end of the channel member. The web member for the first channel member 40 includes a plurality of first openings 46 and the web member for the second channel member 42 includes a plurality of second openings 48. When the channel members 40 and 42 are fixedly attached to each other, the first and second openings 46 and 48 align with each other. Furthermore, with reference once again to Figure 1, the aligned first and second openings are provided at locations along the lengths of the channel members 40 and 42 which correspond to the desired locations for horizontal cable 20 installation. Indeed, as will be discussed in more detail below, the first and second openings 46 and 48 are provided in connection with supporting the attachment of opposite ends of the plurality of horizontal cables 20 to opposite openings in the vertical rail 18.

[37] The openings 46 and 48 may have any desired shape, but in a preferred implementation the openings have square or rectangular cross-sectional shapes.

[38] The first channel member 40 functions to provide reinforcement or stiffness to the assembly with the second channel member 42 to form the vertical rail 18. The first channel member 40 further functions in connection with supporting vertical rail 18 for retention of ends of the plurality of horizontal cables 20. Also, the first channel member 40 provides space for cable adjustment as will be described herein.

[39] It will be understood that the vertical rail 18 on the left end of the panel 10 has an identical, but mirrored, configuration to the vertical rail 18 on the right end of the panel 10.

[40] Figure 8 illustrates a perspective view of the vertical rail 18 with an end cap 50 mounted each end of the channel member 42. A threaded opening 52 is formed each end cap 50. The end cap 50 is secured to the channel member 42 by any suitable means (including, for example, by welding). In a preferred embodiment, the end cap 50 is attached to the channel member 42 in a position where the outer surface of the end cap is flush with the end surface of the channel member 42. In this configuration, it will be understood that the channel member 40 mounted to the channel member 42 will have a slightly shorter length than the channel member 42 in order to account for the thickness of the end cap 50.

[41] Reference is now made to Figure 9 illustrates details of the assembly of a vertical rail 18 to a top or bottom rail 12 or 14. At selected correspondingly (opposite) positioned ones of the openings 24 at the ends of the rails 12 and 14, attachment is made to the opposed ends of each vertical rail 18. Mounting hardware 32 is used to make the attachment. The mounting hardware 32 may, for example, comprise a bolt, screw or other threaded connector as known in the art with the threaded shaft of the hardware extending through the opening 24 in the rail web to engage the threaded opening 52 provided in the end cap 50 of the vertical rail 18.

[42] The open end of the channel member 42 for each vertical rail 18 is closed by a cover plate 56 (show in phantom view in Figure 9 and perspective view in Figure 10). Mounting hardware 58 is used to secure the cover plate to the vertical rail. The mounting hardware 58 may, for example, comprise a bolt, screw or other threaded connector as known in the art with the threaded shaft of the hardware extending through the cover plate to engage the opening 46 of the channel member 40 for the vertical rail 18. A standoff member 60 of appropriate length is installed on the shaft of the mounting hardware 58 to ensure that the cover plate 56 is properly positioned relative to the open end of the channel member 42.

[43] Reference is now made to Figure 11A which illustrates an exploded perspective view of a clamping system configured to engage a first end of the horizontal cable 20. Figure 1 IB shows an assembled cross-sectional view. The cable 20 is formed of a cable member 70 that is made of metal, for example, stainless steel. The cable member 70 may be of a wound or woven or solid (rod) type as desired and is to some degree flexible along its length. At the first end, a uni-directional clamp fitting 72 is attached. The fitting 72 includes a body 74 formed of a flange member 76 and a shank member 78. A threaded opening 80 extends through the flange member 76 and shank member 78. The shank member 78 may, for example, have an outer shape in the form of a square or rectangle generally conforming to the size and shape of the openings 46 and 48 provided in the vertical rail 18. The cable member 70 extends through the opening 80. A compression member 82 includes a plurality of fingers 84 which surround the cable member 70. The compression member 82 fits within the opening 80. The opening 80 further includes a tapered portion 86. When the outer surface of the fingers 84 engages the tapered portion 86 of the opening 80, the fingers 84 function to clamp on to the outer surface of the cable member 70. A bias spring 90 is also inserted into the opening. A threaded cap 92 engages the threaded opening 80 and when tightened compresses the bias spring 90 to apply a bias force against the compression member 82. The threaded cap 92 includes an opening 94 extending therethrough. The cable member 70 passes through the opening 94. When biased by the spring 90, the fingers 84 clamp against the cable member 70 and obstruct movement of the cable member 70 in the direction of arrow 96. However, movement of the cable member 70 in the direction of arrow 98 is permitted because such movement of the cable member 70 moves the compression member 82 in the direction of arrow 98 to release the clamping action of fingers 84.

[44] Reference is now made to Figure 1 1C which illustrates an exploded perspective view of a clamping system configured to engage a first end of the horizontal cable 20. Figure 1 ID shows an exploded cross-sectional view. At the first end of cable 20, a clamp fitting 72' is attached. The fitting 72' includes a body 74' formed of a flange member 76' and a shank member 78'. An opening 80' extends through the flange member 76' and shank member 78'. The shank member 78' may, for example, have an outer shape in the form of a square or rectangle generally conforming to the size and shape of the openings 46 and 48 provided in the vertical rail 18. The cable member extends through the opening 80'. The body 74' further includes a compression member 82' formed of a plurality of fingers 84' which surround the cable member. The outer surface of the fingers 84' is threaded. A cap 92' includes a threaded opening 94' extending therethrough. The cable member 70 passes through the opening 94'. The inner diameter of the opening 94' is tapered 96' at one end. When the cap 92' is secured to the compression member 82', the outer tapered surface 98' at the end of the fingers 84' engages the tapered inner surface 96' of the opening 94' causing the fingers to clamp on to the outer surface of the cable member and obstruct any movement of the cable member. However, by loosening the cap 92', movement of the cable member through the fitting 72' is permitted.

[45] Reference is now made to Figure HE which illustrates a second end of the horizontal cable 20. The cable 20 is formed of the cable member 70 as described above. At the second end, a threaded swage (adjustable) fitting 100 is attached. The threaded swage fitting 100 includes a threaded member 102 and a shank member 104. The shank member 104 is a hollow tubular member sized to receive the end of the cable member 70 which is fixedly attached within the shank member 104. The shank member 104 may, for example, have an outer shape in the form of a square or rectangle generally conforming to the size and shape of the openings 46 and 48 provided in the vertical rail 18. The threaded member 102 likewise is sized to fit through the openings 46 and 68. A nut 106 is provided to be installed on the threaded member 102 and it is sized larger than the openings 46 and 48.

[46] Reference is now made to FIGURES 1 1F-1 1G which illustrate an alternative embodiment for a clamping system configured to engage an end of the horizontal cable 20. FIGURE 1 IF shows a perspective view of the clamping system, and FIGURE 11G shows a cross-sectional view. At the end of cable 20, a clamp fitting 172 is attached. The fitting 172 includes body 174 formed by a flange member 176 and a shank member 178. An opening 180 extends through the flange member 176 and shank member 178. The shank member 178 may, for example, have an outer shape in the form of a square or rectangle generally conforming to the size and shape of the openings 46 and 48 provided in the vertical rail 18. The cable extends through the opening 180. The fitting 172 further includes a compression member 182 formed of a plurality of fingers 184 which surround the cable member. One end of the compression member 182 is threaded 186 to engage a correspondingly threaded opening 188 of the shank member 178. The outer surface of the fingers 184 is threaded. A cap 192 includes a threaded opening 194. The cable member 70 passes through the opening 94'. The inner diameter of the opening 194 is tapered 196 at one end. When the cap 192 is secured to the compression member 182, the outer tapered surface 198 at the end of the fingers 184 engages the tapered inner surface 196 of the opening 194 causing the fingers to clamp on to the outer surface of the cable and obstruct any movement of the cable member. However, by loosening the cap 192, movement of the cable through the fitting 172 is permitted.

[47] Reference is now made to Figure 12A which illustrates an end view of vertical rail 18 with an installed clamp fitting 72 (of Figures 11A-1 1D). The flange member 76 is sized larger than the opening 46 in the first channel member 40 and the shank member 78 is sized to pass freely through the openings 46 and 48 in the channel members 40 and 42. Figure 12B shows a perspective view of the installed clamp fitting 72 on vertical rail 18.

[48] Reference is now made to Figure 13 A which illustrates an end view of vertical rail 18 with an installed threaded swage fitting 100 (of Figure HE). The nut 106 is sized larger than the opening 46 in the first channel member 40 and the shank member 104 and threaded member 102 are sized to pass freely through the openings 46 and 48 in the channel members 40 and 42. Tightening of the nut 106 on the threaded member 102 permits adjustments to be made as to the tensioning of the cable 20. Figure 13B shows a perspective view of the installed threaded swage fitting 100 on vertical rail 18.

[49] Reference is now made to Figure 14 which illustrates an end view of a cap member 110 that is configured for installation over the top rail 14. Figure 15 illustrates the cap member 1 10 in an installed position. The cap member 1 10 is formed of one or more U- shaped channel members 1 12 which may comprise a base member 112a and an ornamental member 1 12b. The base member 112a is designed for press or interference fit over the channel member 22. The ornamental member 1 12b is secured to the base member 112a through any suitable means (including, for example, welding, adhesion, etc.) and includes ornamental features 114 as desired (only one non-limiting example of such ornamentation being shown).

[50] In an alternative embodiment, the open end of the top rail 14 may be closed or covered using other means. For example, Figure 16 illustrates the use of a wooden member 1 16 which can be secured to the top rail 14 using any suitable means (including, for example, a clip mechanism and hardware attachment).

[51] There may exist certain installations, such as with stairs or other sloped terrain, where a perpendicular panel configuration like that shown in Figure 1 is not preferred. In such cases, it would be preferred to install a panel that is configured to have the top and bottom rails and cables of the panel run parallel to the slope as shown in Figure 17A.

[52] The panel 10 is accordingly configured to support racking so as to follow undulating terrain, stairways or ramps. For example, the panel may be racked to an angle up to about 35°. In this configuration, the connection between the vertical support members 16 vertical rails 18 and both the bottom rail 12 and top rail 14 permits other than perpendicular mounting. Additionally, the brackets used to attach the ends of the bottom rail 12 and top rail 14 to the posts 8 permits other than perpendicular mounting. More detail is provided below and in connection with Figures 17B- 17G.

[53] To support this installation, the panel includes a hinge 140 for connecting the ends of the vertical support members 16 to each of the rails 12 and 14. See, Figure 17B. The hinge 140 provides a pivot point 142 between a rail bracket 144 and a support bracket 146. In the illustrated configuration, the support bracket 146 includes a pair of opposed flanges 148 and the rail bracket 144 includes a tab member 150 that is inserted between and pivotally coupled to the flanges 148. The rail bracket 144 may be attached to the rail 12/14 using the included opening 24 and mounting hardware. The support bracket 146 may be attached to an end of the support member 16 using mounting hardware, or alternatively may be integrally formed at the end of the support member 16.

[54] To further support that installation, the panel includes a hinge 160 for connecting the ends of the vertical rails 18 to each of the rails 12 and 14. See, Figures 17C- 17D. The hinge 160 provides a pivot point 162 between a first bracket 164 and a second bracket 166. In the illustrated configuration, the first bracket 164 includes a pair of opposed flanges 148 and the second bracket 164 includes a tab member 170 that is inserted between and pivotally coupled to the flanges 168.

[55] In order to support angled attachment of the ends of the cable, the vertical rails 18 are configured such that an angled tab 172 is cut out from the web member 174 of the first channel member 40 at each opening 46. See, Figures 17E-17G. A first end of the angled tab 172 remains attached to the web member 174 while a second end of the angled tab 172 is bent inwardly towards the web member 176 of the second channel member 42. In an embodiment, the second end of the angled tab 172 is engaged (for example, welded) against the inner surface of the web for the second channel member 42 (as shown at reference 180). The opening 46 still aligns with the opening 48 on the second channel member 42 and receives the fitting 178 which is attached to the cable end (see, Figures 1 1A-1 1D for examples of the fittings). The angle with which the tab 172 is bent may, in a preferred embodiment, be equal to about 30-40°. It will be understood that the angle of the tab 172 may be selected to account for the slope of the stairs or sloped terrain at which the panel is to be installed. The alignment of the openings 46 and 48 is made in accordance with a range of permitted slope installations. To support such a range, the opening 48 in the second channel member is oversized with respect to the fitting.

[56] Although preferred embodiments of the method and apparatus of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth and defined by the following claims.