Abstract:
A modular railing system is disclosed which is based on commercially available tubing, which is connected into a railing by especially designed fittings, which connect to each other and the rails and posts of the railing system to allow all possible standard rail configuration. All connections are thereby held together by mechanical connections, instead of welded connections.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This application claims priority of U.S. provisional application Ser. No. 60/293,040 entitled “Quick Rail System”, filed May 23, 2001, such application being incorporated herein by reference. 

   FIELD OF THE INVENTION 
   This invention relates generally to railings, and, more particularly to modular systems suitable for commercial and private railings and balustrades. 
   BACKGROUND OF THE INVENTION 
   Metal railing systems, but more especially stainless steel railing systems, presently on the market usually require components to be welded together to form the required shapes and frames. This can only be achieved in a workshop environment, and is very time consuming due to the required polishing of the welded seams. On modular metal systems, which do exist, the connections are either complicated, unsuitable for consumer installation or unsightly, making most of these systems only suitable for factory or some commercial installations. 
   In addition, the requirements of many building authorities for vertical spacing of spindles or similar components in balusters to prevent small children from falling through the gaps, makes the use of existing stainless components prohibitively expensive, as those systems are labor intensive and/or require many fittings. 
   It is therefore an object of this invention to improve the ease of installation and construction of railings for decks, balconies, marine docks, tennis courts, and other applications, which require a barrier for safety, esthetics or a separation. 
   It is a further object of this invention to offer the lowest possible number of components with which to cover virtually all variations encountered in the above applications, and to provide components in such a way, that the installation can be done by moderately skilled consumers with very simple tools, or by professional contractors in far shorter installation times than is possible presently. A special feature of the system is the possibility to use either vertical spindles or balusters, or to use virtually any horizontal cable or wire system on the market today, as determined by the architect, and/or in accordance with any relevant building regulations. 
   It is a further object of this invention to offer maximum corrosion resistance and an essentially maintenance free railing system, yet be price competitive with other materials, which do not offer these advantages, through the use of innovative design and manufacturing of the individual components. 
   SUMMARY OF THE INVENTION 
   The objects set forth above as well as further and other objects and advantages of the present invention are achieved by the embodiments of the invention described herein below. 
   The invention is based on commercially available stainless steel (or other material) tubing, which is connected into a railing, or into a framework by especially designed fittings, which allow all possible standard rail configuration. The common item to all such fittings is a special dovetail connector, which accepts all fittings, and which is easy to attach to the tubing, yet provides a safe and largely tamperproof connection. 
   The outer framework of the tubing is very similar for virtually all applications, whether the inside consists of commercially available horizontal wire or cable systems, or uses the spindles in a baluster system, which is part of this invention, except that the lower tubing may be omitted for the horizontal cables. 
   Whereas most installations require vertical tubing or “uprights” to be mounted on a horizontal surface, it is sometimes desirable to attach uprights to a vertical surface, and therefore the system has been designed for both possibilities. 
   It is also a common requirement for steps to lead from or to the railing, and for these steps to either be in line or at right angles (either left or right) to the railing. All four possibilities are covered in this invention, as are all possible angles of such steps either up or down, using the identical fitting. 
   Also common to the system is, that all connections may be held together by mechanical connections, instead of welded connections. The connections may further be held together by a commercially available epoxy, yet the system only relies on the epoxy to prevent rattles or vibration, and will stay together safely through the mechanical connections even if the epoxy fails, has been badly applied, or is not there. 
   For a better understanding of the present invention, together with other and further objects thereof, reference is made to the accompanying drawings and detailed description and its scope will be pointed out in the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1   a  is a pictorial view of a mounting base of this invention; 
       FIG. 1   b  is a bottom view of the mounting base of this invention; 
       FIG. 2   a  is an exploded pictorial view of a base bracket for mounting on a vertical surface; 
       FIG. 2   b  is a pictorial side view of the base bracket mounted on a vertical surface; 
       FIG. 3   a  is a partial cross-sectional view of a dovetail connector of this invention with a connecting screw; 
       FIG. 3   b  is an exploded view of the dovetail connector of this invention shown with a connecting screw extending therefrom; 
       FIG. 4   a  is a pictorial view of a straight version of a rail connector of this invention; 
       FIG. 4   b  is a pictorial view of a left version of a rail connector of this invention; 
       FIG. 4   c  is a cross-sectional view of a right version of a rail connector of this invention; 
       FIG. 4   d  is a pictorial view of a right version of a rail connector of this invention; 
       FIG. 5   a  is a pictorial view of a straight version of an adjustable rail connector of this invention; 
       FIG. 5   b  is a pictorial view of a left version of an adjustable rail connector of this invention; 
       FIG. 5   c  is a pictorial view of a right version of an adjustable rail connector of this invention; 
       FIG. 5   d  is a pictorial view of a male rail adaptor of this invention; 
       FIG. 6   a  is a pictorial view of one embodiment of a post cap used with a railing system of this invention; 
       FIG. 6   b  is a pictorial view of a second embodiments of a post cap used with a railing system of this invention; 
       FIG. 7  is a side view of a railing system of this invention with spindles in a balustrade; 
       FIG. 8  is a side view of a railing system of this invention using commercially available wire rope systems; and 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The railing system of the present invention comprises a plurality of vertical tubes or posts, one or more horizontal rails extending between adjacent posts, and a modular connecting means for connecting the vertical posts to the horizontal rails. Posts are installed on either a vertical or horizontal surface through a mounting base, either alone or in combination with a base bracket. 
     FIGS. 1   a  and  1   b  show an illustration of the mounting base  10  used for all posts or uprights. The base  10  features a spigot  12 , which fits snugly inside a standard tube (not shown). The base may also have recessed holes  16  for attachment to a surface or other railing system component by bolts or screws. The base  10  is preferably symmetrical, and can therefore be turned 180 degrees, which is of benefit since it reduces the amount of prefabricated base assemblies which need to be offered for use with the present invention. An upright standard tube or post can be fitted on site to the spigot  12  of the base  10  using an epoxy, or could be supplied with the base  10  as a welded and polished assembly having the correct height, thus saving on installation time. It is also possible to use the base  10  for a horizontally oriented tubular component, such as when connecting a horizontal rail component to a pre-existing wall. 
     FIG. 2   a  is an illustration of a base bracket  14  for use in vertical mounting in the mounting base  10  of the present invention. The base bracket  14  is used when the railing needs to be mounted on a vertical surface  15 , such as shown in  FIG. 2   b , inwards and over the top of the surface  15 . The top flange  17  of the base bracket  14  is shaped in such a way as to accept the mounting base  10  and to provide a strong support against side loading from any direction. In  FIG. 2   a , the top flange  17  is shown with an aperture of the same size as the spigot  12  of the base  10 . However, in an alternate embodiment (not shown), the top flange  17  may also be a solid layer of material. If recessed holes  16  are used in the base  17 , the top flange  17  may also have recessed holes  16  to receive screws or bolts for attachment. The recessed holes  16  in the base  10  can be provided with screws  18  of a suitable size to allow the mounting base  10  to be connected to the top flange  17  of the base bracket  14 . Attached to the top flange  17  at a right angle is a side flange  19  capable of being attached to a vertical surface  15 , as shown in  FIG. 2   b , through bolts, screws or other means, such as adhesives, known in the art depending upon the material of that surface. 
   In another embodiment of the base bracket  14 , the base bracket  14  is manufactured reversed. That is, the base  14  will be a mirror image of the embodiment shown in  FIG. 2   a , which will allow the post to be mounted away from the vertical surface  15  as opposed to inwards over the vertical surface  15 . The same features and requirements of the base bracket  14  discussed above will apply. 
     FIGS. 3   a  and  3   b  illustrate of a dovetail connector fitting  20  for use with the present invention. This fitting is the common mechanism used to fix all other connective fitting components to the posts, with the exception of the base  10  and bracket  14 , and serves to connect any vertical tube to any horizontal tube. The dovetail connector  20  has several unique features. 
   The backside  22  of the dovetail connector  20  is shaped to a radius, which allows a perfect fit to the outside of a standard tube and is attached to the post. In a preferred embodiment, the dovetail connector back  22  has a short stub or spigot  24  and the standard tube or post has an aperture capable of receiving the stub or spigot which is used for initial location on the tube, and which greatly increases the shear strength vertically and horizontally when the system is in use. A commercially available glue or epoxy may also be used to secure the backside  22  of the dovetail connector to the post. 
   The dovetail connector underside  26  is shaped to perfectly complete the circular cross-section of any of the fitting components used in conjunction with the dovetail connector  20 . This is aesthetically pleasing and offers no sharp corners or edges, as the connecting screw  28  is also recessed into that curved surface. The dovetail connector top  30  has a hole  32 , which lines up with the recessed hole  34  in the underside  26 . A suitable screw  28 , which is commercially available but might have to be modified in length, is inserted into an aperture  34  on the underside  26  of the dovetail connector, passes through an aperture  32  in the top edge  30 , which provides a perfect alignment, and finally enters a threaded hole inside each of the fitting components used in conjunction with the dovetail connector  20 . When the screw  28  is tightened, the dovetail connector  20  and the matching fitting component are tightly connected and complement each other similar to a simple puzzle. 
   To facilitate alignment of the connecting screw  28  during assembly, and to prevent such screw from getting lost, it is preferable to fit a commercially available rubber “O” ring  36  of suitable size over the screw  28  in such a way, that the end of the screw is flush with the top edge  30  of the dovetail connector  20 . This screw  28  is therefore “pre-loaded” for final assembly. 
   In one preferred embodiment, the dovetail connector  20  has a center opening  38  to allow small electric wires and the like to pass from the horizontal tubes into the vertical tubes, thus allowing LED lights to be installed. In yet another embodiment, the dovetail connector  20  has a recessed hole  40  which can be used to permanently fasten the dovetail connector  20  to the upright tube, either by welding, or by sheet-metal screw, or by a suitable rivet. 
     FIGS. 4   a-d  show illustrations of a rail connector fitting used in conjunction with the dovetail connector  20  described above. A straight rail connector  40 , shown in  FIG. 4   a , allows rails to be in line, i.e. 180 degrees with respect to each other, with a possibility of 5 degrees variation either way, if required. The left rail connector  42 , shown in  FIG. 4   b , and right rail connector  44 , shown in  FIG. 4   d , are identical to the straight rail connector, except the left connector  42  and right connector  44  each have a shortened wing  46  with respect to wing  48 , which allows them to be placed next to each on the post such that the sides having the shortened wing  46  are adjacent thus forming any 90 degree to 170 degree angle with respect to each other. Angles from 60 degrees to 90 degrees can be achieved by using the same left and right but the shortened wing  46  will have to be trimmed back by grinding it to suit the desired angle. 
   Referring also to  FIG. 4   c , there are several features common to all three fittings. The wings  46  and  48  are designed in such a way as to fit perfectly around the outside of a given tube, and to blend the horizontal tube into the vertical tube. Apart from being aesthetically very pleasing, as there are no sharp edges or corners, the wings  46  and  48  serve to further take significant side loads against the railing, such as those being experienced when a heavy person falls against it. In combination with the short stub  24  on the dovetail connector  20 , which takes the smaller vertical load, and also contributes to horizontal loads, the rail system can take very significant side (horizontal) loads, which are essentially being limited only by the choice of tubing used. 
   The rail connector underside  50  is open and designed in such a way as to accept the dovetail connector  20  inside where it becomes hidden like a simple puzzle, except for the small exposed underside of it, which complements and closes the opening perfectly. An opening  41  on the end of the rail connector opposite the wings  46  and  48  is shaped to receive the end of a rail component. 
   Preferably, the rail connector internally threaded hole  52  near the top is designed to accept the end of the connecting screw  28  “pre-loaded” into the dovetail connector  20 . 
     FIGS. 5   a - 5   c  show illustrations of the stair rail connectors which have been designed in three versions, a straight stair rail connector  56 , a left adjustable rail connector  54  and right adjustable rail connector  58 . The adjustable rail connectors are used to connect railings for up or down stairs to a standard railing. Each stair rail connector  54 ,  56  and  58  is identical to the rail connectors  40 ,  42  and  44  described above and shown in  FIGS. 4   a - 4   d , except that end  41  of is replaced by a conventional knuckle joint  59  in the stair rail connectors  54 ,  56  and  58 . Thus, the left adjustable rail connector  56  and right adjustable rail connector  58  each have a shortened wing, which allows them to be placed next to each other on a post such that the shortened wings are adjacent, just as a left rail connector  42  and right rail connector  44  may be placed next to each other. Further, a left rail connector  42  or right rail connector  44  may be placed next to a right stair rail connector  58  or left stair rail connector  54 , respectively, by locating the sides of the connectors having a shortened wing adjacent to each other. In addition to all the features embodied in the standard rail connectors the three fittings have additional common features. 
     FIG. 5   d  shows an adjustable male rail adaptor  60  that fits into the knuckle joint  59  of the stair rail connectors  54 ,  56  and  58 . A suitable connecting screw is used which is commercially available. This arrangement allows the stair rail to be positioned at an angle within a vertical plane with respect to a post, and thus the same fitting can be used for a handrail for a stairway to either go up or done. 
   All possible standard uses of a connected stair handrail are covered such as a straight in-line connection, a left and right connection, and all of those either going up or down. A commercially available recessed screw fixes the up or down angle once selected. 
     FIGS. 6   a  and  6   b  show two embodiments of post caps  62  for use with the present invention to close the top of the vertical tube. Those skilled in the art will recognize that several varieties of caps may be used in the railing system, thus allowing for different appearances at a low cost. For example, the embodiment shown in  FIG. 6   a , the post cap  62  has a flat top surface, while in the embodiment shown in  FIG. 6   b , the post cap  62  has a domed crown. 
   Referring also to  FIG. 7 , the post caps  62  will be fitted onto the top of a rail post or tube  78 . Preferably, a commercially available glue or epoxy is added, which has the simple function of preventing a possible loss of the cap  62 . If the railing system  70  is fitted with LED lights  64 , the small size electric wires  75  from each horizontal section can be reached and connected if the cap  62  is removed, and subsequent access for maintenance or replacement is possible. 
     FIG. 7  shows an illustration of an embodiment of the railing system  70  of this invention with the tubular components being vertical spindles in a baluster type arrangement. Depending on the building code, a maximum distance between each spindle  72  may be predetermined which governs the spacing between the tubes. At the desired spacing, holes that match the outside diameter of the spindles  72  are drilled into the underside of the top horizontal rail  74  and the top side of the lower horizontal rail  76 . 
   The spindles  72  consist of identical pieces of straight rod, which has a slight chamfer at each end to allow easier inserting into the holes. The length of each spindle  72  is identical, and is determined by the desired distance between the top rail  74  and bottom rail  76 . A section is assembled on the floor by simply inserting the spindles  72  into the holes of the bottom rail  76  and the top rail  74 . The length of the spindles  72  determines the total height of the baluster, since they touch the inside of the horizontal rails at the lowest and the highest points. The completed section is held together temporarily by tape, rubber “bungee cord” or similar, and then slotted into the four dovetail connectors  20  attached to the rail post  78  from the top and pushed down. Once the four hidden screws have been tightened, there is no possible movement by the spindles  72  as they are captured and held tight by the top rail  74  and bottom rail  76 . 
     FIG. 8  represents a rail system  70  using horizontal wire rope  80  strands or similar commercially available cable systems which pass through each upright tube or rail post  78  at the desired height. Each horizontal wire rope  80  is attached to the end posts  82  and is tightened. The resulting horizontal pulling force obtained by the tensioning acts to compress the horizontal tubes and thus further strengthens the completed rail system  70 . The rail system  70  of this invention may be used with many possible attachments and is not limited to the examples described herein. In one embodiment, as shown in  FIG. 8 , LED Lights  64  are attached to the railing. Wiring  75  for such LED lights is threaded through the rails and posts to make, the railing more aesthetically pleasing. 
   Although the invention has been described with respect to various embodiments, it should be realized this invention is also capable of a wide variety of further and other embodiments.