RAIL MOUNTING APPARATUS AND METHOD

Related Field Of The Invention

The present invention relates to fence rail mounting apparatus and method, and in particular, to rail mounting bracket that is capable of withstanding substantial fence loadings without failure, and that allows rails to be mounted at various angles to the bracket.

Background

Synthetic fences and railings having at least their exteriors made of vinyl, PVC, plastic or other synthetic materials (e.g., materials that can be molded in an injection mold, extruded or pultruded) are used as cost effective replacements for wood and/or metal fences and railings in numerous circumstances. Such synthetic fences and railings can be easier to install, and are substantially maintenance free. Such synthetic fences and railings are typically assembled from post and railing components, each such component made of a synthetic material(s) which typically can be, e.g., a molded, extruded or pultruded. Such synthetic post and railing components typically have a rigid exterior and a hollow interior for receiving various reinforcing components made of, e.g., plastic, wood, or metal, or in some cases reinforced with concrete. Once the composite posts and rails are assembled/constructed, they are secured together to obtain a synthetic fence or railing. Numerous techniques have been developed for assembling such synthetic fences and railing, and in particular, for securing a composite rail to a post or other support structure (e.g., the side of a building). Most such techniques require a mounting bracket for attaching a synthetic railing to a post (more generally, to a "support structure"), the bracket is first secured to its support structure, and then a synthetic rail end is secured to the bracket. However, various esthetic and structural difficulties have not been heretofore adequately addressed for securing such a synthetic rail and a bracket together. For example, securing a synthetic rail end with the bracket can require manually maintaining the rail in position or alignment while securely fastening the bracket to the post. Additionally, since the synthetic rail may have to be secured to the bracket at an angle other than perpendicular to a vertical support structure upon which the bracket is mounted (e.g., when providing railings for stairs between vertically positioned posts) such manual alignment of the rail is made even more difficult.

Another difficulty in assembling synthetic fences and railings results from the perception that such synthetic fences and railings will not withstand the side impacts (or various other loadings) as effectively as their counterpart wood or metal fences or railings. Accordingly, various building regulations have been put in place requiring such synthetic fences and railing to withstand very high impacts and loads from various directions. In many instances, the failure point of such synthetic fences and railings has been at the railing mounting bracket and/or the attachment of the railing thereto. For example, the railing may detach from the bracket and/or the bracket may deform. Additionally, since the bracket, and its various support structure and railing fasteners (e.g., screws, clips, etc.), are metal, it is very desirable esthetically to hide such hardware when the synthetic fence or railing is fully assembled. Although covering plates for hiding such hardware are available, such covering plates may not easily attachable to their brackets, and once attached cannot be detached without damaging at least the covering plate.

Accordingly, it is desirable to have a synthetic rail mounting bracket that addresses and substantially alleviates the above-described difficulties with heretofore available synthetic rail mounting brackets.

Description of Terms Moldable materials: Materials that can be molded according to molding techniques such as compression, transfer, and injection molding, extrusion, and pultrusion.

Synthetic fencing, posts, rails and components thereof: These terms, respectively, refer to fencing, posts, rails and components thereof that provide at least some of the following attributes: (a) such components are manufactured from a synthetic or a non-naturally occurring material such as vinyl, PVC, plastic or another polymer based compound(s), or composite including such a synthetic material, (b) such components are manufactured using a molding technique such as injection molding, extrusion, and pultrusion, wherein a ftowable material is shaped into a rigid fencing components, generally having a hollow interior, and (c) such components are assembled/constructed into fence posts and rails by combining such components together with reinforcing structural materials such as metal, wood, and concrete, wherein such reinforcing structural materials are provided in a hollow interior the components.

Summary of the Invention

A rail mounting system is disclosed for mounting a rail (e.g., a stair, walkway, or fence railing) to a support structure, and a method for performing and using the same is also disclosed. The rail mounting system includes a novel bracket that serves as an intermediary apparatus between, e.g., a fence or banister rail, and a support structure. Thus, a rail may attach to the bracket after the bracket has been attached to a support structure (such a support structure maybe, e.g., the side of a building, a post, a column, a beam, a wall or other rigid members to which a rail can be fixedly attached). The bracket is particularly useful in that once the bracket is secured to a support structure, a rail (more precisely, a rail end) may be easily placed on the bracket for supporting the rail in a desired position, wherein the rail can be subsequently firmly secured to the bracket. In particular, a rail end may be aligned on the bracket by placing the rail end within a rail holding portion of the bracket that includes side supports, and may include a support for the bottom edge of the rail. Thus, the rail can be positioned in the rail holding portion wherein it is supported on the bracket in a properly aligned position until the rail can be firmly secured to the bracket.

Moreover, the rail may be attached to the bracket in any one of a plurality of orientations, e.g., for a vertical support structure surface having the bracket thereon, the rail may extend substantially horizontally, extend downwardly (e.g., the corresponding acute angle between vertical and the rail being approximately 60 degrees or less), or extend upwardly (e.g., the corresponding acute angle between vertical and the rail also being approximately 60 degrees or less). To readily provide such variation in rail orientations, the bracket may include a plurality of rail supports for supporting the rail at at least two different angular orientations. Thus, when the rail is oriented substantially perpendicular to a planar face of the bracket, a first of the rail supports may be used, and when the rail is angled either downwardly or upwardly from the bracket face by, e.g., a deviation from a perpendicular to the face of the bracket by an angle greater than approximately a 30 degrees, a second rail support may be used.

The rail mounting system may also include a bracket cover for covering the bracket and the end of a rail attached thereto. The bracket cover provides an esthetically pleasing exterior that hides the bracket, the rail end and the (any) fasteners used to secure the bracket and the rail end together.

The rail mounting system may further include a bracket attachment component, wherein this component can be secured in place between the bracket and the support structure. Thus, such a bracket attachment allows a bracket having a fixed contour for its surface facing a support structure to be attached to a support surface having a different surface contour. In particular, the contour of a first side of the bracket attachment (facing the back side of the bracket) mates with the bracket, and a second side of the bracket attachment (facing the surface of the support structure) conforms to the contour of the support structure surface.

Further description of advantages, benefits and patentable aspects of the present invention will become evident from the accompanying drawings and description hereinbelow. All novel aspects of the invention, whether mentioned explicitly in this Summary section or not, are considered subject matter for patent protection either singly or in combination with other aspects of the invention. Accordingly, such novel aspects of the present invention disclosed hereinbelow and/or in the drawings that may be omitted from, or less than fully described in, this Summary section are fully incorporated herein by reference into this Summary. In particular, all claims of the Claims section hereinbelow are fully incorporated herein by reference into this Summary section.

Brief Description Of The Drawings Fig. 1 shows a perspective view of one embodiment of the rail mounting system 18, and in particular, shows an embodiment of a bracket 20 to which the rail 26 is to be secured.

Fig. 2 shows the embodiment of the rail mounting system 18 of Fig. 1, wherein the bracket 20 is secured to a support structure 38 and a rail 26 is secured to the bracket.

Fig. 3 shows a face-on view of the bracket 20 together with various embodiments of fasteners 52 for attaching the bracket to a support structure and/or attaching a rail to the bracket 20.

Fig. 4 shows a side view of the bracket 20 together with a dashed profile of the end of a rail 26, wherein the rail is supported on the bracket at an angle (e.g., 45°) to the front face 34 of the bracket.

Fig. 5 is a perspective view showing the components of both the bracket and the bracket cover 28 that mate together for securing the bracket cover over both the bracket and the rail end joined to the bracket.

Fig. 6 shows a more detailed view of the cover lock 112 of the bracket 20.

Fig. 7 shows a top view of the cover lock 112.

Fig. 8 shows the internal structure of an embodiment of the bracket cover 28.

Fig. 9 shows an exterior view of an embodiment of the bracket cover (28a), wherein the bracket cover can be used for covering the bracket 20 when a rail 26 attaches to the bracket at an angle substantially different from orthogonal to the front face of the bracket.

Fig. 10 shows a side view of the bracket cover 28a in place for covering the bracket 20 and the end of a rail 26 which is attached to the bracket so that the rail extends upwardly away from the bracket.

Fig. 11 shows a perspective view of an embodiment of a bracket attachment 59 which serves as an intermediary component between embodiments of the bracket, and a support structure 38. In particular, such a bracket attachment 59 (and variations thereof) allow a bracket having a fixed contour of its surface for facing a support structure (e.g., back face 36, Figs. 1 and 4) to be attached to a support surface having a different surface contour (e.g., including a corner).

Fig. 12 shows an internal structure of the bracket attachment 59 shown in Fig. 11.

Fig. 13 shows an alternative embodiment of the bracket attachment 59, wherein the raised portion 61a assists an installer in properly mounting a bracket thereto.

Fig. 14 shows another embodiment of a bracket attachment 59 for attaching to a curved support structure 38.

Fig. 15 shows another embodiment of a bracket attachment 59, wherein the raised bracket alignment portions 61 are positioned across the width of the bracket attachment rather than lengthwise as shown in Figs. 13 and 14. Additionally, this figure illustrates that bracket attachments can be fitted to a support structure surface so that a rail 26 extending therefrom at substantially any angle by adjusting the bracket attachment profile 69. Fig. 16 shows a face-on view of a guardrail assembly 204 constructed using the rail mounting system 18 for securing the rails 26a and 26b to the posts 208.

Fig. 17 shows a guardrail assembly 204 specimen undergoing horizontal load testing to determine, in particular, the performance of the brackets 20.

Fig. 18 shows a guardrail assembly 204 specimen undergoing inclined load testing to determine, in particular, the performance of the brackets 20.

Fig. 19 shows another embodiment for the bracket (20a) of the rail mounting system 18 together with a "T" shaped rail 26T for attaching to the bracket 20a.

Figs. 20 through 22 show side views of the bracket 20a with a rail 26T supported thereon at various angular orientations. Additionally, these figures show the cross sections of various embodiments of bracket covers 28b-28d attached to the bracket 20 a.

Fig. 23 shows another embodiment of both the bracket (20b), and a corresponding bracket attachment (59b).

Detailed Description Fig. 1 shows an embodiment of the rail mounting system 18. The rail mounting system 18 includes a bracket 20 for mounting an end 24 of a rail 26 thereto (e.g., a synthetic rail, or alternatively, a wood, or metal rail). The rail 26 may be, e.g., up to ten feet in length (Fig. 1 does not show such a length of the rail 26 according to scale), and may have cross sectional dimensions of, e.g., less than eight inches by eight inches. The bracket 20 is correspondingly dimensioned to appropriately mate with the rail end 24. Additionally, the rail mounting system 18 includes a bracket cover 28 (e.g., Figs. 1 and 8) for covering the bracket 20 once the rail end 24 is secured to the bracket 20 (as shown in Fig. 2). The bracket cover 28 may be manufactured from a moldable material(s) such as, e.g., vinyl, PVC, plastic, and the like. The bracket cover 28 includes a central channel 30 extending through the thickness 31 of the bracket cover, wherein a front end opening 29 of the central channel (furthest from the rail end 24) tightly, but slidably, follows the outer shape of the rail 26, and when traversing through the thickness 31 toward the rail end 24, the bracket covering expands outwardly about the rail 26 until the opposite or attachment end 32 of the bracket cover is of sufficient size to entirely enclose the bracket 20 and any fasteners required to secure: (a) the bracket and rail end together, and (b) the bracket to a support structure (e.g., support structure 38, Fig. 2). hi particular, the bracket cover 28 can be slid on the rail 26 toward the joined bracket 20 and rail end 24 for attaching to the bracket (as is described hereinbelow). Thus, when the bracket cover 28 is secured to the bracket 20, the bracket cover entirely covers the joined bracket and rail end 24, such as the joined bracket and rail end of Fig. 2.

Referring now to the bracket 20, the bracket includes a plate 33 having a front face 34 and an opposing back face 36 (occluded in Fig. 1). These faces have dimensions that are, e.g., one to three centimeters larger, in both their length and

width, than the cross section of the rail end 24 for joining to the bracket 20. In at least some embodiments, the bracket is a die-cast #3 zinc part having thickness 40 (Fig. 1) in a range of 0.25 cm to 0.7 cm. However, in other embodiments, the bracket 20 may be manufactured from a zinc alloy, stainless steel, a high strength plastic (e.g., polyvinyl chloride (PVC), thermoplastics; polyurethane, polyethylene (and/or high density variations thereof), polypropylene, nylon, polycarbonate, butyrate, PETG, propionate, ABS plastic, polystyrene, styrene (e.g., ASA and similar variations thereof), a polyacetal resin such as Delrin), high strength resins (e.g., epoxy resins), aluminum (or an alloy thereof). When the bracket 20 is secured to a support structure 38 (Fig. 2), e.g., a post or the side of a building, it is preferred that the back face 36 entirely contact the support structure. Ignoring for the moment the dashed lines 44 of Fig. 1, since a typical support structure 38 will likely have a vertical planar surface, the back face 36 may be substantially flat or planar with the exception of the holes and extrusions that indent toward the front face 32 and/or pierce the thickness 40 of the bracket 20. However, the back face 36 may be curved, as illustrated by the dashed lines 44, so that the back face follows a surface contour of a non-planar support structure 38 upon which the back face seats (e.g., the support structure may be a column or cylindrical post).

The bracket 20 includes a number holes therethrough for securing the bracket to a support structure 38. Referring to Fig. 3, there are three attachment holes 48 along each bracket side 50 for providing fasteners 52 (e.g., screws 52a, threaded bolts 52b, rivets 52c, expandable shaft fasteners 52d, nails (not shown), and the like) therein to attach the bracket 20 to the support structure 38. Additionally, there are two inner columns of holes, each having three holes 54 for securing the bracket 20 to the support structure 38 with fasteners 52. Note that the holes 54 are tapered so that the heads of fasteners 52 secured in these holes can be substantially flush with the front face 34. As will become evident from the description hereinbelow, the reduction (or complete exclusion) of any protrusion of such fastener heads out from the front face 34 is desirable in that the end 24 of a rail 26 covers an area of the front face containing the holes 56, and preferably abuts against this area.

The bracket 20 also has two large holes 56 vertically oriented relative to one another. These holes 56 provide a reduction in the bracket material needed to manufacture the bracket 20. Additionally, the holes 56 may be helpful to a person mounting a rail 26 to a bracket 20. In particular, for a synthetic rail 26, such as the rail shown in Fig. 1, the person mounting the rail may wish to fit the bracket 20 onto a

rail end 24 prior to the bracket being attached to the support structure 38, e.g., so that he/she can view where various fasteners 52 (screws, etc.) will contact rail interior reinforcements (e.g., reinforcements 58, Fig. 1). Moreover, such holes 56 maybe used for aligning the bracket 20 on a support structure 38. For example, a bracket attachment 59 is shown in Fig. 11, wherein this attachment is positioned on a corner of a support structure 38. The bracket 20 can be aligned onto the front surface 57 of the bracket attachment 59 by inserting the cylindrical raised portions 61 into the holes 56 of the bracket. Accordingly, once the bracket 20 is positioned on the bracket attachment 59, the bracket and the bracket attachment 59 can be secured to the support structure 38 by appropriate fasteners 52 (e.g., 52a, 52b, 52c, or 52d) that extend through the holes 48 and 54 of the bracket, and respectively through the holes 62 and 63 of the bracket attachment. Note that the holes 62 and/or the holes 63 may be asymmetrically offset from an axis 65 of points equally spaced from each of the raised portions 61. In a similar manner, the holes 48 and 54 may be correspondingly asymmetrically offset from an axis (not shown) of points on the bracket front face 34 that are equally spaced from each of the holes 56. Such asymmetric alignment of holes can assist in securing the bracket 20 with the bracket attachment 59 since the corresponding holes in the bracket and the bracket attachment will only align when the bracket is in a desired orientation to the bracket attachment. Thus, by requiring a person to position the bracket 20 correctly on the bracket attachment 59, he/she is more likely align the bracket 20 as shown in Fig. 1 (instead of upside down). Fig. 12 shows the side of the bracket attachment 59 that faces the support structure 38. Note that each of the holes 62 and 63 are provided within reinforced tubes 67 that extend from the front surface 57 to the surface of the support structure 38. In the embodiment of the bracket attachment shown in Fig. 13, the lower cylindrical raised portion 61 has been replaced by a triangular raised portion 61a. When this embodiment is used with an embodiment of the bracket 20 having correspondingly shaped holes 56 (e.g., the lower hole 56 being triangularly shaped rather than circular), there can be only one way to align the bracket 20 on the bracket attachment 59 (e.g., the triangular raised portion may have a side that extends beyond the perimeter of the upper cylindrical portion 61). Moreover, for the person installing the bracket 20 and the attachment bracket 59, the triangular raised portion 61a can assist the person with orienting the bracket attachment properly on the support structure 38 in that the raised portion 61a appears to point to the end of the bracket attachment that should be the uppermost.

Fig. 14 shows another embodiment of the bracket attachment 59, wherein this embodiment is used as an intermediary component between a support structure 38 having a curved surface and the bracket 20.

Fig. 15 shows yet another embodiment of the bracket attachment 59, wherein this embodiment is for securing the bracket 20 to a corner of a support structure 38 such that the front surface 57 is tilted approximately 22 degrees from one of two adjacent support structure sides (not shown) that meet at a support structure corner (also not shown), wherein a contour of these adjacent sides and their mutual corner mates with the contour 69. Note that in this embodiment, the raised portions 61 are aligned across the width of the bracket attachment 59 instead being aligned across the length of the bracket attachments (as in the previous embodiments). Moreover, instead of mating with the holes 56 of the bracket 20, the raised portions 61 here mate with the holes 54 that are nearest to the center of the front face 34 (Fig. 3). Note that raised portions 61 here are also offset so that the remaining bracket holes 48 and 54 only align with the holes 62 and 63 when the bracket 20 is properly positioned on this bracket attachment 59.

Returning now to the description of the bracket 20, Figs. 1-7 show various protrusions extending outwardly from the front face 32 of the bracket 20. Upper pair of rail supports 60 (Figs. 1 and 4) are provided as such protrusions upon which the bottom side 64 of a rail end 24 rests when it is mounted on the bracket 20 so that the rail 26 extends outwardly from the bracket in a direction approximately perpendicular to the front face 32 (e.g., the rail extends at an angle within a range of ± 30 degrees of being perpendicular to the front face). In one embodiment, each of the upper rail supports 60 extends approximately one centimeter from the front face 32 for supporting on its upper surface 66 a rail end 24. Each of the upper rail supports 60 may have a corresponding opening 68 adjacent to it (and above it in the operable position of Fig. 1). Only a lower portion of the thickness 72 (Fig. 4) of each upper rail support 60 attaches to the bracket 20 with a remaining upper portion of the thickness occluding the corresponding opening 68 through the front face 32. The reduced amount of bracket material attaching each upper rail support 60 to the remainder of the bracket 20 is sufficient for supporting a rail 26 while it is being further secured to the bracket. However, this reduced amount of bracket material also allows the upper rail supports to be easily broken off or detached from the remainder of the bracket 20 with pliers or other gripping tool.

The upper rail supports 60 can be broken off in the event that the lower rail support 76 is to be used in supporting the rail end 24, at least during the process of firmly securing the rail end 24 and the bracket 20 together. The lower rail support 76 may extend outwardly from the front face approximately 0.5 centimeters. The lower rail support 76 is used for supporting a rail end 24 when the rail 26 is pitched at an angle of more than, e.g., 30 degrees from being perpendicular to the front face 32. Fig. 4 shows a dashed outline of a side view of a rail end 24 supported by the lower rail support 76 (it is assumed that the upper rail supports 66 were previously broken off). Note that the lower rail support 76 can also be used for supporting a rail end 24 cut for fitting flush with the front face 32, wherein the rail 26 extends upwardly from the bracket instead of downwardly as shown in Fig. 4. In fact as shown in Fig. 10, the outline of the rail end 24 shown in Fig. 4 need only be flipped bottom to top so that the upper most portion of the rail outline is positioned on top surface 80 of the lower rail support 76. Additionally projecting outwardly from the front face 32 is a pair of rail side supports 84 and 88 (Figs. 1-6). hi the embodiment of Fig. 1, each of the rail side supports 84 and 88 are mirror images of one another, and each extends perpendicularly from the front face 32 approximately two centimeters (at their furthest points). Additionally, each of the rail side supports 84 and 88 has a thickness 90 of approximately 0.4 centimeters. However, such dimensions are illustrative since alternatives to such dimensions are possible. Each rail side support has an inner surface 92 (Fig. 3), and an outer surface 94 on the opposite side to the inner surface. The inner surfaces 92 face one another. The rail side supports 84 and 88 are substantially parallel to one another and are spaced apart by a distance that is substantially the width "w" (Fig. 1) of the rail end 24 so that when the rail end 24 is positioned between the rail side supports, the rail end simultaneously (and slidably) contacts both inner surfaces 92. Thus, when a rail end 24 is positioned on the bracket 20 (e.g., one of the upper or lower rail supports), the rail end is prevented from shifting or moving laterally by the rail side supports 84 and 88. Accordingly, the rail end 24 can be maintained in a desired alignment with the bracket 20 during the process of securing the rail end to the bracket. In particular, there are rail securing holes 98a and 98b on each of the rail side supports 84 and 88 (Fig. 1) for receiving rail fasteners 96 (e.g., screws, expandable shaft fasteners, threaded bolts or the like, such as the fasteners 52 of Fig. 3) used for securing the rail end 24 (and the reinforcements 58 therein) to the bracket 20 as shown in Fig. 2. Note that if a

threaded bolt is used mating nuts may be fastened to the end of the bolt in the interior of the rail 26, or if the bolt extends from a first hole of one of the hole pairs 98a or 98b through the other or second hole of the pair, then the nut can be attached to the portion of the bolt extending from second hole. Additionally, note that once the rail end 24 is secured to the rail side supports 84 and 88, these side supports (with their fasteners 96) provide the primary attachments that secure the bracket and the rail 26 together.

Each of the rail side supports 84 and 88 further includes a central recessed portion 100 (Fig. 2) of reduced height from the front face 32. This recessed portion of each rail side support is beneficial in securing a fastener 52 (e.g., a screw, threaded bolt, rivet, or the like) in the middle hole 48 adjacent to the side support's the recessed portion 100. In particular, the recessed portion 100 allows a person securing the bracket 20 to a support structure 38 to more easily tighten a fastener 52 in this adjacent hole 48 using any appropriate tool (screw driver, bolt tighter, rivet gun, hammer, etc.). Moreover, each middle hole 48 has, on the outer surface 94 adjacent thereto, a cylindrical recess 104 that provides greater clearance for tightening (or untightening) a fastener 52 in such a middle hole.

Furthermore, the recessed portion 100 is useful in combination with the alignment tabs 106 (Figs. 5 and 8) of the bracket cover 28 for aligning the bracket cover on the bracket 20 so that bracket cover is properly secured thereto as is described hereinbelow. In particular, when the bracket cover 28 is properly positioned for covering the bracket 20, each of the alignment tabs 106 fits within one of the recessed portions 100.

Additionally, each of the rail side supports 84 and 88 is reinforced on its outer surface 94 by reinforcements 108 for further strengthening the rail side supports from deforming when an attached rail 26 sustains a lateral impact.

Adjacent to each end of each of the rail side supports 84 and 88 is a cover lock 112 (e.g., Figs. 1, 5 and 6) for attaching the bracket cover 28 (e.g., Figs. 1 and 5) over both the bracket 20 and the rail end 24 mounted thereto. As described above, the front end of the bracket cover 28 includes a front end opening 29 that follows the outer shape of the rail 26 so that once the rail end 24 is securely attached to the bracket 20 (as in Fig. 2), the bracket cover then can be slid on the rail toward the joined bracket and rail end. The embodiment of the bracket cover 28 shown in Figs. 5 and 8 includes four cover locking projections 120 for inserting into the four cover locks 112, one such projection 120 per cover lock. Each of the cover locks 112 may

be identical. Accordingly, only one such cover lock 112 is provided with detailed labeling in the figures (e.g., Figs. 6 and 7). Each cover lock 112 includes an outer wall 124 connected to the adjacent outer surface 94 by a connecting wall 128 (Figs. 1 and 7). An interior 132 (Figs. 6 and 7) is provided that is bounded by the two walls 124, 128, and a portion of the outer surface 94. The interior surface 136 (Fig. 7) of the outer wall 124 and the opposing portion of the outer surface 94 each include a barb 140 that is angled toward the front face 32 (Fig. 6). The edges 144 (Fig. 7) of the barbs 140 are spaced apart a slightly smaller distance than the thickness 148 (Fig. 5) of the corresponding projection 120 so that for securing the bracket cover 28 to the bracket 20, the corresponding projection enters the interior 132 by forcing the barbs 144 further apart. Accordingly, when an attempt is made to remove the bracket cover 28, the barb edges 144 are biased to bite into the bracket cover material of the projections 120 thereby resisting removal of the bracket cover from the bracket 20. In at least some embodiments, for a rail 26 having a cross sectional size of less than, e.g., 400 sq. cm, a force of approximately between five and twenty-five pounds is required to disengage the projections 120 from their corresponding cover locks 112. Note that in one embodiment, the cover lock insertion end of each projection 120 can be roughened on the sides that contact the edges 144, and/or each projection 120 may have a greater thickness 148 than the thickness of the projection closer to its attachment to the rest of the bracket cover 28. Thus, when such an enhanced surface roughness and/or enhanced thickness 148 enters the interior 132, the bond between the projection 120 and its corresponding cover lock 112 can be substantially strengthened.

Moreover, there are various ways to permanently attach the bracket cover 28 to the bracket 20 such as by providing glue on the projections 120 prior to inserting them into their corresponding cover locks 112. Alternatively and/or optionally, an oppositely oriented barb may also be provided on the cover lock insertion end of each projection 120 so that each such projection barb couples or mates with one of the barbs 140. In such permanently attached bracket cover 28 embodiments, the bracket cover may only be removed by rendering the bracket cover incapable of being reattached to a bracket 20.

In Figs. 4 and 10, the bracket 20 is shown in use with a rail 26 that is sufficiently angled relative to the plane of the front face 34 (as, e.g., may be required for stair railings) so that the lower rail support 76 supports the rail end 24. In such circumstances, the embodiment of the bracket cover 28 shown in Figs. 1 and 8 is

unlikely to fit onto the bracket 20. Accordingly, an alternative embodiment of the bracket cover (labeled 28a) is shown in Figs. 9 and 10, wherein this alternative embodiment can be used to effectively to attach to a bracket 20 as described hereinabove, and also cover the bracket 20 and the rail end 24 when the rail 26 is angled more than, e.g., 30 degrees from being perpendicular to the front face 34 of the bracket. The cover bracket 28a may be substantially identical to a cover bracket 28 with the exception that:

(a) the end 152 (Figs. 9 and 10) of the bracket cover 28a has a cutout 154 to accommodate the more acute angle between the rail 26, and the front face 34; and

(b) in order to provide a close fit between the rail 26 and the edge 156 of the front end opening 29, the edge 156 is shifted toward the end 152, and the slope of the surface 160 (Fig. 10) of the material of the bracket cover 28a (adjacent to the edge 156) is angled at least 60 degrees from the front face 34.

It is important to note that the cover bracket 28a can be used both for a rail 26 that extends downwardly from the bracket 20 (e.g., Fig. 4), and for a rail 26 that extends upwardly from the bracket (e.g., Fig. 10). Thus, to use the bracket cover 28a for a downwardly extending rail 26, the bracket cover is flipped so that the cutout 154 is above the rail rather than below it.

Utilization of the bracket 20 and its corresponding bracket cover 28 (28 a) has been generally described above. However, for further clarity, the rail mounting system 18 maybe used according to the following steps:

Step 1 : Orient and secure a first bracket 20 to a first support structure 38 by placing fasteners 52 within the holes 48 and causing the fasteners to enter or otherwise attach to the first support structure 38. Alternatively, the bracket 20 may be secured to the first support structure 38 by gluing, welding, banding, or securing the bracket 20 onto projections (not shown) extending from the first support structure 38, wherein such projections enter at least one of the holes 48, and/or one of the large holes 56 (e.g., such projections may have a threaded central bore into which a threaded bolt 52b may be secured to hold the bracket 20 on the first support structure 38). Note, as a substep, if a bracket attachment 59 is to be used, the bracket attachment and the bracket 20 are mated together in the proper orientation and jointly

attached to the support structure 38. However, in some embodiments of the bracket attachment 59, there may be holes in addition to the holes 62 and 63 that align with corresponding holes of the bracket 20, wherein such additional holes may be used to first secure the bracket attachment to a support structure so that subsequently the bracket 20 can be aligned on the bracket attachment and attached to both the bracket attachment and the support structure as described heremabove. Additionally, note that embodiments of posts (or other support structures) may be manufactured with features corresponding to the bracket attachments being integral with each such post. Accordingly, such posts (or other support structures) may reduce the amount of measuring an installer must perform since the positions for attaching the brackets 20 is predetermined on the posts. Step 2: For a second support structure 38 that is secured in a stationary position the distance of a desired rail length away from the first support structure, orient and secure a second bracket 20 to the second support structure 38 by placing fasteners 52 within the holes 48 and causing the fasteners to enter or otherwise attach to the first support structure 38. Note that the various substeps and embodiments described in Step 1 also apply here as well. In typical embodiments, the first and second brackets will be at the same vertical offset from an end of their corresponding support structures. However, in alternative embodiments, the first and second brackets 20 may be vertically offset different amounts on their corresponding support structures so that when the rail 26 is provided therebetween, the rail extends from a relatively high position on one of the support structures to a relatively low position on the other support structure.

Step 3: If either of end of the desired rail is to form a vertical angle that is, e.g., greater than or equal to approximately 30 degrees from an orthogonal alignment with a front face 34 of the corresponding one of the first and second brackets for supporting the rail end, then detach the rail supports 60 from this corresponding bracket using pliers or another gripping tool. Step 4: Obtain the desired rail 26 of the desired rail length and having rail ends 24 that are of a desired angle so that each of the rail ends can be

supported on a corresponding one of the first and second brackets 20. If necessary, such a rail 26 may be obtained by cutting a rail that is too long and/or by cutting one or both rail ends 24 at an angle that is appropriate for mounting the cut rail on the first and second brackets. Step 5: Slide two bracket covers 28 onto the rail 26 obtained from Step 3, wherein the bracket covers are oriented so that their front end openings 29 face on another on the rail 26. If the rail 26 is to be oriented at an angle less than approximately 30 degrees from the front face 34 of one of the first and second brackets, then the corresponding one of the bracket covers for covering this bracket may be substantially functionally similar to the bracket cover 28 shown, e.g., in Figs. 1 and 8. Alternatively, if the rail 26 is to be oriented at an angle greater than approximately 30 degrees from the front face 34 of one of the first and second brackets (as in Figs. 4 and 10), then the corresponding one of the bracket covers for covering this bracket may be substantially functionally similar to the bracket cover 28a shown, e.g., in Fig. 9. Step 6: Place each of the rail ends 24 between the rail side supports 84 and 88 of a corresponding one of the first and second brackets 20 to which the rail end is to be secured, wherein the rail end is supported on the rail supports 60, if they are still attached, and the lower rail supports otherwise.

Step 7: With the rail 26 supported on the first and second brackets, secure the rail 26 to each of the first and second brackets using, e.g., fasteners 52 as described hereinabove. Step 8: Subsequently, slide the two bracket covers 28 (28a) away from one another and toward a corresponding one of the first and second brackets 20. Attach each bracket cover 28 (28a) to its corresponding (nearest) bracket 20 by mating each of the alignment tabs 106 and the cover locking projections 120, respectively, with a corresponding recessed portion 100 and cover lock 112 as described hereinabove.

LOAD TESTS OF THE RAIL MOUNTING SYSTEM 18

Tests were conducted to determine the structural performance of guardrail assemblies 204 (Figs. 16-18) having the rail mounting system 18 for connecting upper and lower rails 26 (denoted 26a and 26b, respectively) to posts 208. The tests were performed

using 2 inch by 3-1/2 inch die-cast #3 zinc brackets 20 substantially as shown in Figs. 1-3, wherein the plate 33 (Fig. 1) had a thickness 40 of approximately 0.160". Each bracket 20 was attached to their corresponding posts 208 and rails using screws 52a as shown in Fig. 3. More specifically, each bracket 20 was attached to: (a) a support post 208 with six (6) #10 x 1-1/2" Phillips panhead wood screws, and (b) attached to one of the rails 26a and 26b with four (4) #12 x 1" Phillips panhead wood screws. AU screw locations for attachment to the support(s) and rail(s) were pre-drilled. The posts were common 4 x 4 treated Southern Pine with PVC covers. The rails 26a and 26b were synthetic rails as described in the Description of Terms above having a length of 10 feet, hi particular, each of the rails 26a and 26b included a hollow PVC extruded exterior frame having an aluminum reinforced interior, e.g., as shown in Fig. 1. Each of the guardrail assemblies 204 incorporated a midspan support leg 210 located beneath and supporting the bottom rail 26b.

Each of the guardrail assemblies 208 also included a plurality of vertical pickets 212 attached between each of the rails 26a and 26b. Each of the pickets 212 was a synthetic fencing component having a PVC extruded exterior frame with a hollow interior in which an aluminum reinforcing component (not shown) was provided. Each of the pickets 212 was attached to each of the rails 26a and 26b via insertion of the aluminum reinforcing component within each picket into connector holes (not shown) providing access to the interior of each of the rails 26a and 26b.

The brackets 20 were evaluated using the load requirements identified in the following building codes:

(a) IBC-2000 / ICC - International Code Council, published by International Code Council, 900 Montclair Road, Birmingham, Alabama 35213-1206 USA; URL: www.iccsafe.org;

(b) BOCA- 1999 - Building Officials and Code Administrators (Reference ASCE 7-95) published by Published by Building Officials and Code Administrators International, Inc. 4051 West Flossmoor Road, Country Club Hills, IL 60478-5795; (c) SBC-1999 / SBCCI - Southern Building Code Conference International published by International Code Council 900 Montclair Road, Birmingham, Alabama 35213-1206 USA; URL: www.iccsafe.org. In particular, the brackets 20 were tested for determining whether they satisfied the load requirements for guardrails as specified by the above identified building codes.

Rail assembly 204 specimens were tested in a self-contained rigid steel test frame 220 (Figs. 17 and 18) designed to anchor one of the rail assemblies 204 during the application of test loads to be applied. An electric winch (not shown) mounted to the rigid steel test frame was used to induce loads on the rail assemblies for determining, e.g., maximum deflection, load at rail assembly failure, and/or extent of permanent bending. Chains, cables, nylon lifting straps, and load distribution beams 224 were used to impose the test loads on each specimen of the rail assemblies 204. Each applied load was measured using an electronic load cell located in-line between the specimen and the electric winch. Deflections are measured to the nearest 0.01" using electronic linear transducers (not shown).

Each rail assembly 204 was tested by securing its posts 208 into the rigid steel test frame. The rigid test frame 220 rigidly restrained the posts 208 from deflecting. The linear transducers were mounted to an independent reference frame to record movement of reference points on various components of the specimen being tested (e.g., end points and mid-point of the rails 26a and 26b) to determine net component deflections. Uniform distributed loads with simple end supports were simulated with 1/4-point loading (i.e., a load distributed evenly over two or four locations equally spaced across the horizontal length of the specimen). Uniform distributed loading conditions with interior support (e.g., Fig. 18), as per SBC top rail loading requirements, were simulated by distributing a load across four equal load points. Test Procedure:

Each rail assembly 208 specimen was preloaded up to a level not exceeding design load (e.g., the load which the rail assembly is designed to withstand). After pre-loading, all load was released and any necessary fixture adjustments were made. An initial load, not exceeding 20% of design load, was applied and initial deflections recorded. Loads were then applied at a steady uniform rate in step loading increments. Each load increment was reached in approximately one minute and deflections were recorded. The load/deflection procedure continued until reaching 2.0 times design load. At 2.0 times the design load, the load was released. After allowing a minimum period of one minute for stabilization, load is reapplied to the initial load used at the start of the load/deflection procedure and deflections were again recorded and used to analyze recovery. For tests that require ultimate loads greater than 2.0 times design load, loading is reapplied and increased at a steady uniform rate until failure occurred or the required ultimate load is reached. The testing time was

continually recorded from the application of initial test load until the maximum test load is reached.

The tables hereinbelow are representative of results from the test procedure. Tables 1 through 3 are the test results from a test of a first specimen of the rail assemblies 204, wherein a uniform horizontal design load on the top rail 26a of the specimen was approximately 50 pounds per linear foot (lpf) of the top rail 26a. The tests performed simulated various uniform horizontal loads both above and below the design load. Each simulation applied equal loads at two or four points equally distributed across the rail 26a of the specimen as shown in Figs. 17 and 18. For the first table (TABLE 1) following, the columns can be described as follows:

Load Level: The multiplicative factor indicative of the relative amount of the design load to which the specimen was subjected (e.g., a load level of 0.2 represents a load that is 20% of the design load).

Test Load: The actual load (in pounds) to which the specimen was subjected. Test Data Top Rail Deflection (inches)

End- 1 : Identification of one of the ends of the top rail 26a. Each number of this column is a measurement (in inches) of the deflection of the rail 26a end represented by End-1 when the load in the same row was applied to the specimen. Mid: Each number of this column is a measurement of the deflections of the rail 26a midway between the posts 208. End-2 Identification of the end of the top rail 26a opposite from End-1.

Net This is an abbreviation for "Net Deflection". Each "Net" value was computed as follows: average the deflection values for the "End-1" and "End-2" columns in the same row as the Net entry to be computed, then subtract the "Mid" value for the same row from this average.

Deflection Analysis y=mx The values in this column are obtained from a linear regression of the values in the "Deflection" column. Thus, for a linear equation of the form y = mx, "x" can be interpreted as the test load applied to a specimen of the rail assemblies 204, and "y" can be interpreted as the corresponding deflection of the specimen.

Deflection The maximum displacement from initial configuration of a specimen of the rail assemblies 204.

TABLE 1

IBC and BOCA Design Load; 50 plf Uniform Load on Top Rail ²

For the second table (TABLE 2) following, the columns can be described as follows: Load Level: Same as for TABLE 1.

Test Load: Same as for TABLE 1. Test Data Top Rail Deflection (inches)

Post: Each number of this column is a measurement of the deflections of the post 208 at the rail 26a end identified as End-1.

Rail: Each number of this column is a measurement of the displacement of the rail 26a end identified as End-1. Note, this column is identical to the End-1 column of TABLE 1.

Net: Each number of this column is a measurement of the net displacement of the rail 26a relative to the post 208 to which the rail end End-1 is attached. Note that the net displacement is determined by subtracting the corresponding rail deflection value (in the same row) from the post deflection value (in the same row). Displacement Analysis y=mx Same as for Table 1 above.

Displacement Same as for Table 1 above.

TABLE 2

For the third table (TABLE 3) following, the columns can be described as follows:

Load Level: Same as for TABLE 1. Test Load: Same as for TABLE 1. Test Data Top Rail Deflection (inches)

Post: Each number of this column is a measurement of the deflections of the post 208 at the rail 26a end identified as End-2.

Rail: Each number of this column is a measurement of the deflections of the rail 26a end identified as End-2. Note, this column is identical to the End-2 column of TABLE 1.

Net: Same as for TABLE 2 above. Displacement Analysis y=mx Same as for TABLE 1 above.

Displacement Same as for TABLE 1 above.

TABLE 3

IBC and BOCA Design Load: 50 plf Uniform Load on To Rail ²

Tables 4 through 6 are the test results from a test of a second specimen of the rail assemblies 204, wherein a uniform downward sloping design load on the top rail 26a of the specimen was approximately 112 pounds per linear foot (plf) of the rail 26a at approximately a 63.4 degree downward direction from horizontal as shown in Fig. 18. The tests performed simulated various uniform downward sloping loads both above and below the design load. Each simulation applied equal loads at four points equally distributed across the rail 26a. Note that the columns for each of the tables 4 through 6 have the same interpretations as described above for Tables 1 through 3.

TABLE 4

SBC Desi n Load: (50 Horizontal + 100 Vertical lf Uniform Load on To Rail

TABLE 5

SBC Design Load; (50 Horizontal - 100 Vertical) plf Uniform Load ^: on To Rail

TABLE 6

Satisfactory performance for the above tests is specified in the above- identified building codes. In particular, the performance requirements in these building codes are satisfied when there is a 75% recovery from a load of 2.0 times the design load in both the horizontal and downward sloping application of a uniform top rail load, and additionally, for the horizontal uniform load simulation, an ultimate load of not less than 2.5 times the design load can be sustained without the specimen failing. From the above Tables 1-6 it is apparent that the rail mounting system 18 meets these performance requirements.

Additional Embodiments

Figs. 19 through 22 show an embodiment of the bracket 20a. Additionally, Figs. 20 through 22 show cross sections of three alternative bracket covers 28b, 28c and 28d attached to the bracket 20a (wherein the cross sectioning plane is normal to the front face 34 of the bracket 20a, and includes the axis 300 in Fig. 1) .

The bracket 20a has many features that are substantially the same as those of bracket 20. Accordingly, such substantially identical features are labeled with the same numerical labels used hereinabove for features of bracket 20, and such features will not be further described in the context of bracket 20a.

The bracket 20a is designed to be used with a rail 26 whose cross sectional profile is generally in the shape of a "T". One such "T" rail 26 is shown in Figs. 19 through 22, this rail being labeled 26T. The bracket 20a includes side supports 84a and 88a of reduced length, wherein each of the side supports has a shelf 304 at its

upper end. The shelves 304 function as a support for the rail 26T in a similar manner to the function of the upper pair of rail supports 60 in the bracket 20. That is, the rail 26T can be placed on the pair of shelves 304 for supporting the rail in position until the rail can be secured to the bracket 20a with fasteners 52 as described hereinabove. In particular as shown in Fig. 20, the overhangs 308 contact the shelves 304 for supporting the rail until rail fasteners 96 (e.g., as shown in Fig. 2) can be provided in the holes 98b and through both: (a) the sides 312 of the rail 26T, and (b) the reinforcement(s) 58 (for simplicity, not shown in Fig. 19) provided in the interior 316 (Fig. 19) of the rail. Accordingly, the bracket 20a does not need the upper rail supports 60 shown in Fig. 1.

For rails 26T that extend at a downward incline from the bracket 20a (as shown in Fig. 21), each of the side supports 84a and 88a also include an inclined support 320 for supporting the rail on its overhangs 308. Thus, the bracket 20a does not need the lower rail support 76 shown in Fig. 1. Note, however, that for rails 26T extending upwardly from the bracket 20a, the overhangs 308 contact the shelves 304 for initial support (as shown in Fig. 22), and in particular, the end edge of the each of the overhangs 308 may seat into a corresponding one of the corners 324 formed between the front face 34 and one of the shelves 308.

The bracket covers 28b, 28c, and 28d shown Figs. 20 through 22, attach to the bracket 20a as described above for bracket cover 28 and bracket 20. However, due to the reduced length of the side supports 84a and 88a, each such side support has a single adjacent cover lock 112.

Note that since various embodiments of the bracket 20a can have the same hole patterns for the holes 48, 54 and 56 as shown in Figs. 1 and 3 for bracket 20, the bracket attachments 59 described hereinabove can be used to attach the bracket 20a to a support structure 38.

Fig. 23 shows another embodiment of the bracket (20b) together with an embodiment of a bracket attachment 59b for mating with the bracket 20b. The bracket 20b can be used in a substantially similar manner to the bracket 20a for attaching a railing thereto. However, bracket 20b is particularly useful for "T" rails having sides 312 (Fig. 19) of reduced height, wherein it may be difficult or impossible to secure two spaced apart fasters 52 in each of the rail sides 312 via the rail securing holes 98a and 98b of Fig. 19-21.

As shown in Fig. 23, the bracket 20b can be aligned onto the front surface 57 of the bracket attachment 59b by aligning the holes 62 with the holes 48 of the

bracket, and aligning the holes 63 with the holes 54 of the bracket so that fasteners 52 can be placed through the aligned holes for securing the bracket and bracket attachment to a support structure. In at least one embodiment, note that these corresponding holes in the bracket 20b and bracket attachment 59b will not completely align with one another unless the bracket 20b and the bracket attachment 59b are placed together as indicated by the dashed arrows 328; i.e., if the bracket is rotated 90° (keeping the front face 34 in the plane) the holes in the bracket and the bracket attachment will not align. In other embodiments, the bracket 20b and the bracket attachment 59b can mate together via, e.g., additional holes in the bracket and mating raised portions on the front surface 57 of the bracket attachment as, for example, are shown in Figs. 11 and 13-15.

Several of the above-described methods, techniques, and/or components may have additional alternative embodiments. For example, the cover locks 112 may be provided within the bracket cover channel 30, and the mating locking projections 120 may be provided as part of the bracket 20. Additionally, various types of resilient locking tabs or protrusions and mating catches may be provided (e.g., such as the protrusions 36 and passages 32 of U.S. Patent 6,460,829, filed Jan. 15, 1999 and fully incorporated herein by reference) as a replacement for the cover locks 112 and projections 120. Further embodiments of the rail mounting system 18 can be provided by utilizing various alternative methods, techniques and/or components (e.g., components that are substantially functionally equivalent to the components described herein) such as:

(a) alternative fasteners 52 (e.g., clips providing corresponding functionality, shafts having a locking lever, or the locking pin of disclosed in U.S. Patent

Application 20040261243, filed April 5, 2994, fully incorporated herein by reference);

(b) alternative types of rails 26 (e.g., non-synthetic rails, metal or wood rails, and/or non-hollow rails); (c) alternative techniques for mounting a bracket cover 28 (or 28a-d) to a bracket 20 (or 20b) such as a snap on bracket cover as shown in Figs 3, 3A, and 3B of U.S. Patent 5,873,671, filed Feb. 19, 1997 and fully incorporated herein by reference, or the disclosure of U.S: Patent Application 20040261243;

(d) alternative rail 26 orientations relative to the bracket 20, e.g., embodiments of the bracket 20 wherein the side supports 84 and 88 are parallel to one another, but each are at an angle such as 45° to the front face 34 thereby allowing a rail 26 to fitted between the side supports when the rail approaches the front face 34 from a non-orthogonal angle such as 45°; and/or

(e) alternative support structures 38 (e.g., composite posts of various composition, and walls of various composition, such as concrete, wood, metal, stone, brick, etc.). Additionally, the alternative fence constructing techniques described in the following list of references that are fully incorporated herein by reference:

• U.S. Patent Application having publication number US 2003/0030048 filed June 6, 2002;

• U.S. Patent Application having publication number US 2003/0101673 filed June 5, 2003;

• U.S. Patent 6,682,056 filed Oct. 30, 2000;

• U.S. Patent 6,460,829 filed Jan. 15, 1999;

• U.S. Patent 6,314,699 filed Jan. 15, 1999;

• U.S. Patent 6,202,987 filed Nov. 8, 1999; • U.S. Patent 6,041,486 filed Jan. 28, 1999;

• U.S. Patent 5,988,599 filed Feb. 19, 1997;

• U.S. Patent 5,873,671 filed Feb. 19, 1997;

• U.S. Patent 5,853,167 filed Feb. 19, 1997;

The foregoing discussion of the invention has been presented for purposes of illustration and description. Further, the description is not intended to limit the invention to the form disclosed herein. Consequently, variation and modification commensurate with the above teachings, within the skill and knowledge of the relevant art, are within the scope of the present invention. The embodiment described hereinabove is further intended to explain the best mode presently known of practicing the invention and to enable others skilled in the art to utilize the invention as such, or in other embodiments, and with the various modifications required by their particular application or uses of the invention.