Abstract:
A curved railing system that does not use curved infill panels and has a continuous curved top rail. It uses a series of posts that follow the desired curve. The posts have a bottom rail and space to hold infill panels that may be glass, solid panels, perforated panels, vertical pickets, or cables. All of these infill panels are straight panels that are not curved. A special post cap is installed on the posts. The post cap has pivoting articulating brackets that are used to support and align glass channels. The top rail is a continuous length of railing that matches the desired curve. The top rail is placed over the posts and glass channels. In this way, the entire assembly produces a curved rail design at a lower cost and with less labor than a conventional curved rail.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   Not Applicable 
   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 
   Not Applicable 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to curved railing systems and particularly to curved railing systems that use segmented infill panels. 
   2. Description of the Prior Art 
   Many buildings have decks, porches and balconies (note the works “deck” herein shall include to decks, porches, and balconies) added to them. They provide useful outdoor space and add value to the building from both a utility perspective as well as an aesthetic perspective. One of the more aesthetically pleasing balcony configurations are those that contain one or more radiused or curved sides. While aesthetically pleasing, however, balconies with curved sides can present difficult challenges for those designing and installing the associated railing system. 
   Railing systems are used to provide safety on an elevated deck, as well as providing an aesthetically pleasing element of the overall design. The problem with curved railings is obtaining infill panels (such as glass) that match the curve. Curved glass is expensive. Moreover, fitting the segmented top rail to the construction adds labor cost because the top rail must be custom fitted in the field by making precise miter cuts to join the top rail segments together. It requires considerable skill on the part of the installer to make multiple precision miter cuts. Otherwise, the entire appearance of the railing will be negatively impacted. Because curved railing involve considerably higher costs and require a higher level of skilled labor to install, they are generally limited to high budget projects. Moreover, the use of curved decks is also limited for the same reason. 
   BRIEF DESCRIPTION OF THE INVENTION 
   The instant invention overcomes these difficulties. It is a railing system that accommodates balcony applications with one or more curved sides, yet does not use curved infill panels while utilizing a continuous curved top rail that eliminates the need for miter cuts in the installation. It uses a series of vertical posts that follow the line of a desired curve. The posts have a bottom rail and space to hold infill panels that may be glass, solid panels of metals or plastics, perforated metal or plastic panels, vertical pickets, or cables. All of these infill panels are straight panels that are not curved. A special post cap is installed on the vertical posts. The post cap has pivoting articulating brackets that are used to support and align glass channels. The top rail is a continuous length of railing that matches the desired curve. The top rail is placed over the vertical posts and glass channels. In this way, the entire assembly produces a curved rail design at a lower cost and with less labor than a conventional curved rail. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is perspective view of a section of curved rail according to the disclosed invention. 
       FIG. 2  is a top detail view of the curved rail system, showing the outline of the curved top rail and the position of the posts and infill panels beneath it. 
       FIG. 3  is a partially exploded view of a section of the curved rail. 
       FIG. 4  is a partially exploded view of a section of the rail showing the post cap assembly. 
       FIG. 5  is a detail view of an assembled in-line post. 
       FIG. 6  is a detail of an assembled end post. 
       FIG. 7  is a detail view of an assembled corner post. 
       FIG. 8  is a top view of a post cap. 
       FIG. 9  is a side view of a post cap. 
       FIG. 10  is a bottom view of a post cap. 
       FIG. 11  is a bottom perspective view of a post cap. 
       FIG. 12  is a top perspective view of a post cap. 
       FIG. 13  is a cross-sectional view of the top rail. 
       FIG. 14  is a cross sectional view of a top rail showing full potential range of glass channel positions. 
       FIG. 15  is a cross-sectional view of a glass channel. 
       FIG. 16  is a bottom view of an articulating bracket. 
       FIG. 17  is a side view of an articulating bracket. 
       FIG. 18  is a bottom perspective view of an articulating bracket. 
       FIG. 19  is a top perspective view of an articulating bracket. 
       FIG. 20  is a detail of an infill panel made of perforated metal panels. 
       FIG. 21  is a detail of an infill panel made of vertical pickets. 
       FIG. 22  is a detail of an infill panel made of cables. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring now to  FIG. 1 , a perspective view of a section of curved rail according to the disclosed invention is shown. The main components of the railing system  10  are a series of vertical post assemblies  11 , a length of bottom rail  12  that runs between the vertical post assemblies  11 , a number of infill panels  13  that fit between the vertical post assemblies  11  and rest on the bottom rail sections  12 , and a top rail  14  that sit atop the vertical post assemblies and the infill panels. At the end of the top rail  14  is an end cover  14   a  as shown. The infill panels may be glass, solid panels of metal, perforated metal panels, vertical pickets, or cables. See  FIGS. 20-22 . shows a curved rail at a nominal ten-foot radius. The vertical post assemblies  11  are placed 42 inches on center. Note that infill panels  13  are straight and run diagonally under the rail. Of course, for other radii or curved rail, the dimensions will change accordingly. For example, placement of the vertical post assemblies must be done to keep the infill panels straight under the curved rail. This can be done easily, by first laying out the desired radius for the curve (shown in the dashed lines) and then placing the posts at the spacing needed to keep the infill panels straight and under the rail. Of course, there maybe radii of curves that are too sharp to enable the infill panels and vertical post assemblies to fit under the rail. However, for most general applications, such problems can be eliminated by taking care in the initial design to ensure a useable radius for the rail. 
   This figure also shows two articulating bracket assemblies  20  and an end assembly  21 . The two articulating bracket assemblies are the heart of the system and are discussed in detail below. 
     FIG. 3  is a partially exploded view of a section of the curved rail. At the top of the railing, is the curved top rail  14 . This is normally made of aluminum, although other materials can be incorporated as well. It has a large flat area to allow the diagonal positioning of the glass channel  15 . The glass channel  15  is a length of straight aluminum channel that is attached to the top rail  14  with screws  15   a . Note that, although this element is designated as a “glass channel” its use is not limited to glass infill panels, as is discussed above. A length of vinyl insert  16  is placed within the glass although this element is designated as a “glass channel” its use is not limited to glass infill panels, as is discussed above. A length of vinyl insert  16  is placed within the glass channel  15  to secure and protect the infill panels  13 , which may be glass, metal or plastic. At the bottom of the infill panels  13  is another length of vinyl insert  17  to secure and protect the infill panels. Finally, the bottom rail  12  is attached to the posts, as discussed above. Note that the bottom rail is normally mitered at the posts to ensure a clean fit for the rails. 
     FIG. 3  also shows the some details of the assembly of the post cap. The post cap  20  is secured to the vertical post with screws  20   a . Articulating mounting brackets  25  help to secure the glass channels to the post cap. For a center run, two articulating mounting brackets  25  are normally used. The articulating mounting brackets  25  are pivotably secured to the post caps, as discussed below. This allows the articulating mounting brackets  25  to be positioned properly to align the glass channels  15  with the curve of the top rail (see  FIG. 2 ). Once the base railing sections are all in place and secure, the articulating mounting brackets  25  strengthen the glass channels. Moreover, the adjustability of the articulating mounting brackets  25  aids in the overall installation as the alignment of the components is greatly simplified. 
     FIG. 4  is a partially exploded detail view of a section of the rail showing details of the post cap  20 . As in  FIG. 3 , the top rail  14  is shown positioned above the other railing components. A vertical post  11  is positioned as discussed above. Two lengths of glass channel  15  are shown on either side of the vertical post  11 . Note the screws  15   a  that secure the glass channels  15  to the top rail  14 . As mentioned above, the post cap  20  is secured to the vertical post by screws  20   a . Note that the particular shape of the post cap is discussed in detail below. Note also that the post cap is secured to the top rail by screws  20   f  as discussed below. 
   Here, the articulating mounting brackets  25  are shown clearly. They are secured to the top rail by screws  25   a . The articulating mounting brackets  25  have a generally triangular shape with a hole  25   b  at the apex of the triangle and two mounting block  25   c  at the base corners. The hole  25   b  is positioned on a pivot point on the post cap  20  as discussed below. 
   The mounting blocks  25   c  have a dual purpose. First, they secure the top rail with the screws  25   a . Second, they form a channel in which the glass channel rests. In this way, the glass channels are positioned and strengthened. Moreover, because the articulating mounting brackets  25  can pivot around the mounting hole  25   b , the glass channels can be easily adjusted in the proper position without having to make intricate and precise miter cuts. 
     FIG. 5  is a detail view of an assembled in-line post. In this figure, the vertical post  11  is shown at the bottom of the assembly. The post cap  20  is shown secured to the vertical post with the screws  20   a . The articulating mounting brackets  25  are shown positioned on the post cap  20  and the glass channels  15  are shown positioned between the mounting blocks  25   c.    
     FIG. 6  is a detail of an assembled end post. Here, the railing reaches an end. There is only one length of glass rail  15  extending out from the vertical post  11 . The post cap  20  is attached to the vertical post with screws  20   a  as before. Note, however, that the post cap  20  has been modified. As discussed below, the post caps have two flanges  20   b . These flanges can be cut off as needed. Thus, in  FIG. 6 , one of the flanges has been removed to present a 90-degree corner for the end of the railing. As before, an articulating mounting bracket  25  is shown positioned on the post cap  20  and the glass channel  15  is shown positioned between the mounting blocks  25   c . Of course, for an end installation, only one articulating mounting bracket  25  is needed. 
     FIG. 7  is a detail view of an assembled corner post. In this figure, the post cap  20  is again shown with one flange  20   b  removed. Note that the articulating mounting brackets  25  are shown positioned on the post cap  20  at right angles, to make the corner. As before, the glass channels  15  are shown positioned between the mounting blocks  25   c  of the articulating mounting brackets  25 . 
     FIGS. 5 ,  6  and  7  show the versatility of this system. Using only a few components, any configuration and angular setup (within reasonable design parameters) can be achieved easily and quickly with a minimum of field installation labor. 
     FIGS. 8-12  show details of the post cap  20 .  FIG. 8  is a top view of a post cap  20 . The post cap has a formed shape as shown. On three sides, there are mounting flanges  20   b . On two of the side, cast-in cutting guides  20   c  are shown. As discussed above, these cutting guides are used to make end and corner post caps in the field. On each of the mounting flanges, are mounting holes  20   d . These holes are used to secure the post cap to the top rail with screws  20   f . See e.g.,  FIG. 4 . 
   The post caps  20  have four countersunk mounting holes  20   e  that are used to secure the post cap to the vertical posts  11 . 
     FIG. 9  is a side view of a post cap. Note that the top of the post cap is flat. The countersunk mounting holes  20   e  are shown extending downward from the bottom of the post cap to form spacers  20   g . Note also, the pivot point  20   h  that also extends below the bottom surface of the post cap. The pivot points are used to hold the articulating mounting bracket  25  at hole  25   b.    
     FIG. 10  is a bottom view of a post cap. Once again, the spacers  20   g  are shown as well as the countersunk holes  20   d , and the pivot points  20   h.    
     FIG. 11  is a bottom perspective view of a post cap. The mounting holes  20   d  and the spacers  20   g  are shown as well as the countersunk holes  20   d , and the pivot points  20   h.    
     FIG. 12  is a top perspective view of a post cap. Here again, the mounting holes  20   d  and mounting holes  20   e  are shown as well as the cut lines  20   c.    
     FIG. 13  is a cross-sectional view of the top rail. In this figure, the top rail  14  is shown. Within the top rail is a mounting plate  14   b  that is used to attach the glass channels  15 . 
     FIG. 14  is a cross sectional view of a top rail showing glass channels installed. In this view, the glass channels  15  are shown secured to the top rail using the screws  15   a . Note that two glass channels are shown. In actuality, only one glass channel is used. This figures illustrates the widest range of positions that the glass channel takes as the lower unit is built to support the curved top rail. See  FIG. 2 , which also shows the ranges of positions of the glass channel under the top rail as the curve progresses. In the preferred embodiment, the widest spacing of the glass channels is 3.070 inches on center. 
     FIG. 15  is a cross sectional view of a glass channel  15   
     FIG. 16  is a bottom view of an articulating bracket. Here, the mounting hole  25   b  and mounting blocks  25   c  are shown. 
     FIG. 17  is a side view of an articulating bracket. Here, the mounting blocks  25   c  are shown extending above and below the man body of the triangular articulating bracket. This not only provides additional support for the mounting screws, it also adds substance to better support the glass channels that fit between them. 
     FIG. 18  is a bottom perspective view of an articulating bracket. Note that in this view, the mounting holes are counter sunk. 
     FIG. 19  is a top perspective view of an articulating bracket. 
     FIG. 20  is a detail of an infill panel made of perforated panels. In this figure, the infill panels  13  are shown as perforated panels. These can be either metal or plastic, as desired. 
     FIG. 21  is a detail of an infill panel made of vertical pickets. Here, a number of vertical pickets  30  are shown. The pickets  30  are used in place of a solid infill panel. Although the pickets shown are simple vertical pickets, any other style of pickets may be used. 
   Finally,  FIG. 22  shows cables  34  run between the posts in lieu of a panel. 
   It is possible to use many different materials and styles for the infill panels and the figures shown are not meant to be exclusive or limiting. 
   The present disclosure should not be construed in any limited sense other than that limited by the scope of the claims having regard to the teachings herein and the prior art being apparent with the preferred form of the invention disclosed herein and which reveals details of structure of a preferred form necessary for a better understanding of the invention and may be subject to change by skilled persons within the scope of the invention without departing from the concept thereof.