Abstract:
A cable railing is provided that includes two or more vertical members secured to a surface with a base plate having a horizontal member and two or more holes to affix two or more receiving inserts containing at least one spring, a retainer cap, at least a pair of wedge locks and a receiving insert, one adjustable in a clockwise rotation the second adjustable in a counter clockwise rotation to secure and draw one or more cables taught by a tightening apparatus to enclose decks, balconies, walkways, stairways and other areas.

Description:
BACKGROUND OF THE INVENTION 
     The present application relates to railing systems, in particular to cable railing systems for use in commercial and residential settings, for example, to enclose decks, balconies, walkways, stairways and the like. 
     Cable railing, often chosen for a clean unobtrusive look, is used in both interior and exterior applications. Cable railing generally has less material to obstruct a view than other forms of railing. A drawback, however, is that the fasteners and turnbuckles that are required to tighten the cable rail are exposed. In addition to presenting an industrial look and feel to the cable railing, which may not always be desired or appropriate, these exposed elements are prone to being tampered with and may result in injury. 
     Various other materials, such as glass, have been used to produce a clean unobtrusive look to enclose decks, balconies, walkways and stairways. Glass however is a high maintenance solution requiring constant washing to keep it clean and thus not a ideal solution to overcome the problems associated with traditional cable railing systems. 
     Accordingly there is a need for cable railing which overcomes the limitations of railing systems noted above. 
     SUMMARY OF THE INVENTION 
     In one aspect, a railing system is provided that includes a pair of vertical members; a pair of cable receiving assemblies, each cable receiving assembly attached to one of the pair of vertical members and having a cavity therein with an outwardly facing opening for receiving a cable; and a cable having opposed ends, wherein each of the opposed ends inserted is into an outwardly facing opening and terminated in one of the pair of cable receiving assemblies. 
     In one embodiment, at least one of the pair of cable receiving assemblies includes a tubular receiving insert having inner threads therein, a tubular threaded insert threaded into the receiving insert, the threaded insert having a tapered inner surface, and at least two wedge locks inserted within the threaded insert, each of the wedge locks having a tapered outside surface that acts against the tapered inner surface of the threaded insert and at least one tension surface that clamps onto the cable inserted within the assembly. 
     In one embodiment, the receiving insert is affixed to a hole in a vertical member. 
     In one embodiment, at least one of the receiving insert and the threaded insert fit essentially flush within an outer surface of the vertical member. 
     In one embodiment, the at least one cable receiving assembly includes a spring that pushes the at least two wedge locks outward. The spring may be a coil spring and the cable may be located within the coil spring. 
     In one embodiment, threading the threaded insert increases a tension in the cable. 
     In one embodiment, at least one of the pair of cable receiving assemblies includes a tubular receiving insert having inner threads therein, a tubular threaded insert threaded into the receiving insert, the threaded insert having a tapered inner surface, and at least two wedge locks inserted within the threaded insert, each of the wedge locks having a spherical shape that acts against the tapered inner surface of the threaded insert to clamp onto the cable inserted within the assembly. 
     In one embodiment, each of the pair of cable receiving assemblies includes a tubular receiving insert having inner threads therein, a tubular threaded insert threaded into the receiving insert, the threaded insert having a tapered inner surface, and at least two wedge locks inserted within the threaded insert, each of the wedge locks having a tapered outside surface that acts against the tapered inner surface of the threaded insert and at least one tension surface that clamps onto the cable inserted within the assembly, and wherein the threads of the receiving member of one of the assemblies is opposite the threads of the receiving member of another of the assemblies. 
     In one embodiment, each cable receiving assembly includes a spring that pushes the at least two wedge locks outward. The spring may be a coil spring and the cable may be located within the coil spring. 
     Additional aspects of the present invention will be apparent in view of the description which follows. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a perspective view of one embodiment of the cable railing in use. 
         FIG. 2  is a detail perspective view taken from  FIG. 1 . 
         FIG. 3  is a section view taken from  FIG. 2 . 
         FIG. 4  is a front view of  FIG. 3 . 
         FIG. 5  is a top view of  FIG. 4 . 
         FIG. 6  is a detail view taken from  FIG. 4 . 
         FIG. 7  is a detail view taken from  FIG. 4 . 
         FIG. 8  is a perspective view of the compressed receiving insert. 
         FIG. 9  is a perspective section view taken from  FIG. 8 . 
         FIG. 10  is a perspective view of the threaded insert. 
         FIG. 11  is a perspective section view taken from  FIG. 10 . 
         FIG. 12  is a perspective view of the wedge lock. 
         FIG. 13  is a perspective section view taken from  FIG. 12 . 
         FIG. 14  is a perspective bottom view of the wedge lock. 
         FIG. 15  is a perspective view of the spring. 
         FIG. 16  is a side elevation view taken from  FIG. 15 . 
         FIG. 17  is an exploded perspective view of  FIG. 2 . 
         FIG. 18  is a detail view taken from  FIG. 17 . 
         FIG. 19  is a detail view taken from  FIG. 17 . 
         FIG. 20  is a perspective view of the tightening means. 
         FIG. 21  is a front section view like  FIG. 6  with a tightening means in use. 
         FIG. 22  is a section view of another embodiment of the wedge lock. 
         FIG. 23  is a section view taken from  FIG. 22 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1  a perspective view of one embodiment of the cable railing system  10  in use.  FIG. 1  illustrates one of many possible configurations of cable railing system  10  to surround a perimeter of a deck, balcony and/or to enclose the sides of a stairway. The system generally includes two or more vertical members or posts  12 , at least one horizontal member  14 , such as a handrail, extending between vertical members  12 , and one or more cables  28 , also extending between vertical members  12 , for a typical installation. Vertical members  12  are secured to a surface by fasteners extending through base plates  16 . As can be seen, the railing system  10  provides a very clean look, without exposed fasteners and turnbuckles. Further, cable railing  10  is safer because there are no exposed fasteners or turnbuckles for fingers to get caught in or hands to get, inadvertently, cut by. Another advantage is a more precise installation. A cable railing system  10  can be pre-manufactured to size and does not depend on stretching cables through a field installed post system. 
     The cable railing  10  system is preferably pre-manufactured from information provided by field or design measurements. In this instance, vertical members  12 , horizontal members  14 , base plates  16  and cables  28  are fabricated in a manufacturing facility. In particular, another advantage of the cable railing  10  system is that vertical members  12 , having been cut to length with base plates  16  welded in place, are at this time also fitted with holes  18 , receiving inserts  20 , wedge locks  24 , springs  26  and the other related components. If need be the cable railing  10  system can be completely set up in the fabricating facility to check against field or design measurements. 
     Referring now to  FIG. 2  through  FIG. 8 .  FIG. 2  is a detail perspective view taken from  FIG. 1 .  FIG. 3  is a section view taken from  FIG. 2 .  FIG. 4  is a front view of  FIG. 3 .  FIG. 5  is a top view of  FIG. 4 .  FIG. 6  is a detail view taken from  FIG. 4 .  FIG. 9  is a detail view taken from  FIG. 4 . In one embodiment, the vertical members  12  are constructed from 2 inch by 2 inch tube steel and can be any length. A base plate  16  is welded to the bottom end of the vertical member  12 . One or more holes  18  are drilled through each vertical member  12  so that at least one pair of holes are facing each other. The holes  18  may be approximately 0.75 inches in diameter and spaced incrementally in a vertical direction. In most instances, the vertical dimension between hole-centers may be from about 3 inches to about 4 inches. The holes  18  in the vertical member  12  accommodate the insertion of a cable receiving assembly, which includes receiving insert  20 , a threaded insert  22 , a spring  26 , and a plurality of wedge locks  24 . The receiving assembly is attached to the vertical members  12  by first inserting the receiving insert  20  into each of the holes  18 . After insertion the insert  20  into the hole  18 , the receiving insert  20  is permanently affixed, in hole  18 , for example, using a setting tool which expands the outside portion of the receiving insert  20  to securely attach the insert  20  against the inside and outside surfaces of the wall of the vertical member  12 , as shown. 
     Assembly is continued by inserting at least two wedge locks  24  and one spring  26  into the hollow cavity of threaded insert  22 . Threaded insert  22  is then joined with the inside thread of receiving insert  22  and tightened to securely engage threaded insert  22  and receiving insert  20  for transportation, of the prefabricated cable railing  10  assembly, to the installation location. The spring  26  acts against the receiving insert  20  and/or the threaded insert at the inner end of the assembly, retainer cap  40 , and against the inner end of the wedge lock  24 , thus pushing the wedge lock  24  outwardly. 
     Retainer cap  40  may be constructed of 24 gauge steel in a circular fashion with an approximate inside diameter of about 0.225 inches and an outside diameter of approximately 0.305 inches. Four radii of approximately 0.035 inches are positioned at the quarter points of the circle. The retainer cap  40  is press fit into the end of threaded insert  22  to hold the spring  26  against wedge lock  24 . The approximate overall dimension of retainer cap  40  may be a reference circle of about 0.320 inches. 
     At the installation location, the vertical members  12  are secured to a surface by fasteners extending through base plates  16 . Horizontal members  14  are installed at the top end of vertical members  12 . Next, the cut to size, cable  28  lengths are installed into the access holes at the inside facing ends of threaded inserts  22 . Cable  28 , in one embodiment, is constructed of 0.125 stainless steel 1×19 braded wire. Any slack in the cable  28  is removed by hand and the cable  28  is drawn taught by turning one threaded insert  22  in a clockwise rotation  32  and the opposite threaded insert  22  in a counter clockwise rotation  34 . In both these instances the spring  26  is integrally engaged on the inside of threaded insert  22  and serves to tension a pair of wedge locks  24  in their appropriate place inside threaded insert  22 . As threaded insert  22  is tightened, the pair of wedge locks  24  are put under pressure to secure the cable  28  by biting into the surface of cable  28  as cable  28  is drawn taught by the rotational tightening of threaded insert  22 . 
     It should be further noted that cable  28  can be cut to size to have its cable  28  ends contained by the cable receiving assembly. Also cable  28  can be cut with an overage of material. The cable receiving assembly, being open to the back, allows extra cable  28  to exit the back of the cable receiving assembly. Thus another advantage is cable  28  ends are contained in the vertical members  12  cavity, making field trimming of cable  28  unnecessary. 
       FIG. 8  is a perspective view of an expanded receiving insert  20  and  FIG. 9  is a perspective cross section view taken from  FIG. 8 . Receiving insert  20 , in one embodiment, is constructed from 304 or 316 stainless steel with an approximate outside diameter of about 0.68 inches and approximate length of about 1.2 inches. The exposed flange has an approximate diameter of 0.835 inches. The receiving inserts  20  are manufactured in pairs. One receiving insert  20  has an inside ½-13 right hand machined thread while the other of receiving insert  20  of the pair has a inside ½-13 left hand machined thread. 
       FIG. 10  is a perspective view of the threaded insert  22 .  FIG. 11  is a perspective cross section view taken from  FIG. 10 . Threaded insert  22 , in one embodiment, is constructed from ½-13 threaded rod with an approximate outside diameter of about 0.5 inches and approximate length of about 1.24 inches. The insert  22  has a central cavity extending the length of the insert  22 . The cavity has tapered diameter, which tapers from about 0.188 inches at the outward facing access hole (that receives the cable) to about 0.326 inches at the inward facing access hole. The threaded insert  22  includes a head to accommodate a tightening means  30  or any other hand tool, such as a wrench or pliers, for threading the threaded insert  22  into the receiving insert  20 . The head has approximate dimensions of about 0.3 inches by about 0.5 inches and is configured as a cylinder, with material removed, to create two opposite planer sides. The depth of the head is about 0.188 inches. 
       FIG. 12  is a perspective view of the wedge lock  24 .  FIG. 13  is a perspective cross section view taken from  FIG. 12 .  FIG. 14  is a perspective bottom view of the wedge lock  24 . Wedge lock  24 , in one embodiment, is constructed from ASTM A 108 standard screw stock or similar with a zinc finish and has an approximate width, at its narrow end, of about 0.2 inches and an approximate width at its wide end of about 0.271 inches. The wedge lock  24  therefore has an outside surface that tapers outwardly. The approximate height of the wedge lock  24  is about 0.121 inches. The approximate diameter of the M3.5×0.6 machine thread in the inside surface of the wedge lock  24  is 0.117 inches. 
       FIG. 15  is a perspective view of the spring  26 .  FIG. 16  is a side elevation view taken from  FIG. 15 . Spring  26 , in one embodiment, is constructed from about 0.026 wire with a constant pitch of about 0.05 inches in a clockwise direction of 9 revolutions with a height of about 0.445 inches. The spring  26  may have three loops with no gaps at one end and is ground flat at that end. 
     Referring now to  FIG. 17  through  FIG. 19 .  FIG. 17  is an exploded perspective view of  FIG. 2 .  FIG. 18  is a detail view taken from  FIG. 17 .  FIG. 19  is a detail view taken from  FIG. 17 . The sequence of drawings  FIG. 17  through  FIG. 19  illustrates the assembly order of cable railing  10  in an exploded diagram. At least two vertical members  12  are provided. At least one hole  18  is drilled through the inside facing wall of each vertical member  12 . The holes  18  are approximately 0.75 inches in diameter. The holes  18  accommodate the insertion of receiving insert  20 . After insertion, receiving insert  20  is permanently affixed, in hole  18 , by a setting tool which secures receiving insert  20  to the inside and outside surfaces of the tube wall adjacent to hole  18 . The next step in the assembly is the insertion of at least two wedge locks  24  and one spring  26  into the hollow cavity of each threaded insert  22 . Threaded insert  22  is then threaded into the inside thread of each receiving insert  22  and tightened to securely engage threaded insert  22  and receiving insert  20 . Next, pre-cut cable  28  is installed into the outside facing access holes of threaded inserts  22 . Any slack in the cable  28  is removed by hand and the cable  28  is drawn taught by turning one threaded insert  22  (shown to the left in the illustrations) in a clockwise rotation  32  and the opposite threaded insert  22  (shown to the right in the illustrations) in a counter clockwise rotation  34 . The tightening of the threaded insert  22  causes the tapered inside surface of the threaded insert  22  to act against the tapered outside surface of the wedge lock pair  24  to apply clamping pressure to the cable  28 . This clamping pressure maintains the tension in the cable  28  as the threaded inserts  22  are threaded into the receiving insert  20 . 
       FIG. 20  is a perspective view of the tightening means  30 . The tightening means  30  is constructed of cast, forged or fabricated steel and is approximately 8 inches in length with an approximately 0.25 inch deep by 0.75 inch wide handle containing an articulated bend of approximately 45 degrees. The engagement end of tightening means  30  is cylindrical in fashion and constructed to fit the head of threaded insert  22  and gives clearance to rotate inside of receiving insert  20 .  FIG. 21  is a front section view like  FIG. 6  with a tightening means  30  in use. In some installations it is preferable to not have the head of threaded insert  22  exposed beyond the inside surface of vertical member  12 . In this instance traditional tools, such as wrenches and pliers cannot set the threaded insert  22  to this depth. Tightening means  30  is used to engage the head of threaded insert  22  and set it to a level below the inside surface of vertical member  12 . 
       FIG. 22  is a section view of another embodiment of the wedge lock  24   a  and  FIG. 23  is a section view taken from  FIG. 22 . In this embodiment wedge lock  24   a  can be constructed as a steel sphere. A plurality of steel spheres are positioned to center cable  28  with in threaded insert  22 . Two springs  26   a  may be used in this embodiment to apply opposing forces to hold wedge locks  24   a  in a planer position inside threaded insert  22 . The spheres may be held in place in a circular carrier having a variable diameter, which allows the diameter of the carrier to decrease as the carrier is pushed toward the front end of the assembly within the tapered section of the threaded insert  22 . Cable  28  is inserted and held by pressure from the wedge locks  24 . 
     While the foregoing invention has been described in some detail for purposes of clarity and understanding, it will be appreciated by one skilled in the art, from a reading of the disclosure, that various changes in form and detail can be made without departing from the true scope of the invention.