Abstract:
Top and bottom rails for an outdoor railing system, include a plurality of equally spaced recesses defined in a side of the rails into which spindle ends are fitted. Each of the recesses comprises a multi-sided configuration having an open side defined through an inward edge of the rails so that spindles having a complimentary shaped end can be pressed into the recesses from the sides of the rail.

Description:
RELATED APPLICATIONS 
     This application is a continuation application of Ser. No. 09/252,593 filed Feb. 11, 1999, now U.S. Pat. No. 6,231,031 and incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to railing systems especially suited for outdoor use, and more particularly to a top and bottom rail configuration for such railing systems. 
     Railing systems for any number of outdoor applications are well known. For example, residential decks, pool decks, playgrounds, etc., all utilize any number of conventional railing systems. Such decking and railing systems are typically made of pressure treated lumber particularly suited for outdoor use. With conventional railing systems, spindles are vertically disposed between a top and bottom rail. Typically, the spindles are nailed or screwed onto the flat inwardly facing surfaces of the top and bottom rails. In order to provide the railing system with a “finished” appearance, face boards are typically attached to the side edges of the rails thereby defining a generally U-shaped channel with the rails into which the ends of the spindles extend. However, this conventional configuration has significant drawbacks. For example, the U-shaped channel is a favorite nesting place for any manner of insects, including wasps, bees, and the like. Also, this system requires additional materials, for example the side face boards, and is fairly labor intensive in that the spindles must first be screwed or nailed to the top and bottom rails and then the face boards must be attached to the rails. This process and expense is undesirable, particularly in the residential decking industry wherein homeowners frequently install or build their own deck systems. 
     With another conventional railing system, the spindles are attached to the sides of the top and bottom rail, which are oriented so that their wider sides extend vertically. In other words, the spindles do not extend between the inwardly facing surfaces of the rails, but are nailed or screwed to the longer or wider sides of the rails. The spindles typically include angled ends that “merge” into the sides of the rails. This conventional system also has significant drawbacks. For example, most state building or construction codes require that the rail spindles are not spaced apart beyond a maximum distance. To attach such spindles to the sides of the rails, the spacing must be pre-measured and marked on the rails. Additionally, the spindles also have a tendency to “rack” or bow with respect to the rails over time, particularly with pressure treated lumber wherein the wood tends to alternately lose and absorb moisture. The ends of the spindles tend to pull away from the rails or the spindles bow in the middle and the railing system generally loses its finished uniform look over time. 
     The present invention relates to an inexpensive and simple railing system that overcomes a number of disadvantages noted with prior art systems. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     It is thus a principal object of the present invention to provide an improved railing system particularly suited for outdoor use. 
     An additional object of the present invention is to provide rails for use in outdoor railing systems that eliminate many disadvantages of conventional rails. 
     Still an additional object of the present invention is to provide improved prefabricated rail sections that are relatively easy to install. 
     And yet another object of the present invention is to provide improved top and bottom rails for outdoor railing systems that can accommodate any number of conventional spindles. 
     Still another object of the present invention is to provide improved outdoor railing system rails that help the railing system retain its finished appearance over a longer period of time without additional expense or processes in building the railing system or manufacturing the rails. 
     In accordance with the objects and purposes of the invention, a rail is provided for an outdoor railing system wherein a plurality of generally vertically disposed spindles are attached to upper and lower embodiments of the rail. Each rail includes top and bottom edges with first and second opposite sides defined between the edges along the longitudinal length of the rail. The top and bottom edges generally have a width less than that of the sides such that the rail may have, for example, a vertically oriented rectangular profile. The spindles are attachable to the rail along or against one of the sides. 
     Each rail includes a plurality of generally equally spaced recesses defined along the side in which the spindles are attached. The spindle ends fit into the recesses. Each recess comprises a multi-sided configuration having an open side defined through the bottom edge of the rail so that spindles having a complimentary shaped end can be pressed into the recesses from the sides of the rails. 
     Thus, it should be understood that according to the invention, the rails are not attached at their ends between inwardly facing sections of the top and bottom rail, but are anchored within recesses defined along the sides of the top and bottom rail. In a preferred embodiment, the recesses are generally U-shaped with the open end of the recess defined in the bottom or inwardly disposed edge of the rails. 
     Each recess has a configuration SO as preferably to engage at least two surfaces of a spindle inserted therein to prevent the spindle from twisting within the recess relative to the rail. In this regard, the spindle need not have a shape or profile that exactly matches the configuration of the rail recess so long as the spindle is engaged by the recess to prevent twisting or movement of the spindle relative to the rail. 
     In one preferred embodiment, the recesses comprise a generally flat inner face disposed in a generally vertical plane against which a side of a spindle can abut. The end of the spindle may further abut against the top side of the recess. The sides of the recesses are preferably generally flat and defined in planes generally perpendicular to the inner face. 
     Preferred embodiments of the rails and railing system according to the invention are formed of lumber or wood, particularly pressure treated lumber suited for outdoor use. However, it should be appreciated that the particular materials used in the present invention are not a limitation. For example, the rails may be formed of a plastic or other suitable material. 
     It should also be appreciated that the rails as described herein are suitable for use as a top or bottom rail in a railing system. 
     It should also be appreciated that the rails are also suitable for use as a stair rail wherein the rails are disposed at other than a horizontal angle. For example, the rails will generally follow the slope of the stairs. In this embodiment, the recesses are angled at a non-perpendicular angle relative to the edge of the rail so that the spindles can be attached vertically when the rail is used as a non-horizontal stair rail. 
     The rails according to the invention are also mateable with opposite similarly configured rails such that the sides of the rails having the recesses defined therein are facing or abut each other. In this manner, the recesses align and enclose the spindle ends between the rails. This gives a unique finished appearance to the railing system and allows the rails to accommodate several different styles of spindles that are not particularly suited for attachment to the sides of the rails. For example, many conventional spindles are ornate and have squared ends with flat bottoms that look best when attached between inwardly facing surfaces of the rails. The rails according to the present invention can accommodate such spindles. 
     The present invention also relates to an outdoor railing system, including pre-fabricated rail sections, having top and bottom rail configurations with a plurality of generally equally spaced spindles attached between the top and bottom rails. Each rail configuration includes at least one top and bottom rail as described above. 
     In an alternate configuration of the railing system, two such rails are provided for each top and bottom rail configuration such that the spindles are “sandwiched” between the facing rails. As discussed above, in this configuration the uniquely configured rails can accommodate a vast number of conventional spindles. 
     Preferred embodiments of the rails and railing system will be described below in greater detail through use of the attached figures. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a railing system incorporating the unique rails according to the invention; 
     FIG. 2 is a perspective assembly view of a rail and spindle configuration according to the invention; 
     FIG. 3 is a perspective assembly view of a rail and spindle configuration according to the invention wherein the rail is utilized as a non-horizontal stair rail; 
     FIG. 4 is a perspective view of a stair rail according to the invention; and 
     FIG. 5 is a perspective partial cut-away view of an alternative rail configuration according to the invention utilizing two top and bottom rails. 
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield still a third embodiment. It is intended that the present invention include such modifications and variations as come within the scope and spirit of the present invention. 
     An outdoor railing system, generally  10 , according to the invention is illustrated in FIG.  1 . Railing system  10  is illustrated as a pre-fabricated section of a complete rail for purposes of illustration. The present invention includes such pre-fabricated sections as well as a complete railing system constructed in accordance with the invention. The present invention also includes top and bottom rails  12  separately for use in such railing systems. 
     Conventional outdoor decking and rail systems are typically made from wood, particularly pressure-treated lumber. The present invention includes rails and railing systems made of wood, but is not limited to any particular material. For example, the components of the railing system  10  or rails  12  may be fabricated from any conventional construction material, including plastic, cementious materials, and the like. Any and all such materials suitable for railing systems are within the scope and spirit of the invention. 
     Referring again to FIG. 1, railing system  10  includes upper and lower rails, generally  12 . Each rail  12  includes an outward edge  14  and inwardly facing edge  16 . Opposite sides, including side  18 , are defined between the edges. Rails  12  are preferably oriented so that wider sides  18  extend in a vertical direction. In this regard, rails  12  may comprise a conventional two-by-four or two-by-six oriented as illustrated in FIG.  1 . 
     Spindles  22  are connected or attached to rails  12  along side  18  along the longitudinal length of the rails. It should be appreciated that the present invention is not limited to any particular type of spindles  22 , and that the rectangular profile spindles illustrated in the figures is for illustrative purposes only. 
     A plurality of generally equally spaced recesses  26  are defined along the longitudinal length of rail  12  in face  18 . As is generally illustrated in FIG. 1, ends  24  of spindles  22  rest or are nested within recesses  26 . The recesses are illustrated in greater detail in FIGS. 2 and 3. Each recess  26  has an open side  28  defined in side  18  of rail  12 , and an open end  30  defined in edge  16 . Preferably, a generally flat inner face  34  is defined essentially parallel to side  18 . An end side  33  is defined between generally flat sides  32 . In this regard, in the preferred embodiment illustrated in the figures, each recess  26  is generally U-shaped. 
     Each recess  26  has a size so as to accommodate an end  24  of the spindles. In this regard, end  24  can be pressed into rail  12  from side  18 . The back side of spindle end  24  preferably abuts against flat face  34  and the sides of spindle end  24  preferably abut against sides  32  of recess  26 . Likewise, the end of spindle  24  preferably abuts against side  33  of recess  26 . 
     It should be appreciated that recesses  26  can take on any manner of shape or configuration so long as they engage against enough surfaces of spindle end  24  to prevent the spindles from twisting or torquing relative to rails  12 . The spindle ends  24  may be further secured within recesses  26  by any other conventional means, including nails  38 , adhesives, and the like. 
     The configuration illustrated particularly in FIGS. 1 and 2 provides for a relatively simple means for securing the spindles  22  relative to rails  12  while ensuring that the railing system  10  maintains a professional finished look over a longer period of time. The recesses  26  are preferably spaced apart according to building codes or restrictions so that spindle spacing and measurement is no longer a concern and it is a relatively simple matter to simply press spindles  22  into recesses  26  and nail or otherwise permanently secure the spindles relative to the rails. 
     The depth of recesses  26 , or width of sides  32 , is not particularly critical so long as recesses  26  are sized so as to accommodate spindle ends  24  taking into account shrinkage and expansion of the spindles as they alternately lose and absorb moisture over time. Also, recesses  26  should not be defined so as to structurally weaken rails  12 . 
     For ease of manufacture, recesses  26  are preferably formed as illustrated in FIG. 2 with sides  32  and  33  essentially perpendicular to face  18 . Likewise, innerface  34  is generally parallel to side  18 . This configuration also complements conventional rectangular or square ended spindles. However, it should be appreciated that recesses  26  may be defined by other than flat or straight sides depending on the end configuration of the spindles. It is preferred that at least two sides of the spindle ends abut directly against at least two sides or surfaces of recess  26  so as to ensure that the spindles do not twist relative to rails  12 . 
     Rails  12  according to the invention, and a railing system incorporating rails  12 , may also be used as a conventional stair rail, as illustrated in FIG.  4 . Here, top stair rail  36  and bottom stair rail  37  are illustrated. Rails  36  and  37  are constructed substantially identical to rails  12  as described above with the exception that recesses  26  are at a non-perpendicular angle relative to edge  16 , as particularly illustrated in FIG.  3 . In this manner, rails  22  may extend vertically even though the rails are oriented in a non-horizontal manner, as illustrated in FIG.  4 . It may be preferred that end side  33  is defined so as to extend horizontally at the angled inclination of the rail. Thus, ends  33  act to vertically align the spindles. 
     An alternate preferred railing system  42  according to the invention is illustrated in FIG.  5 . In this embodiment, a first rail  44  and second rail  46  are joined as the top and bottom rails such that recesses  26  in each of the first and second rails face each other. Rails  44  and  46  are generally constructed as described above with regards to rails  12  of FIG.  1 . In the embodiment of FIG. 5, the opposite recesses  26  of the joined first and second rails “sandwich” spindle ends  24 . This configuration gives a unique appearance to the finished railing system in that the spindles appear to be connected between inwardly facing surfaces  48  comprised of joined edges  16 . This configuration also obviously securely locks the spindles within the rails. 
     The embodiment of FIG. 5 is also particularly useful in that it can accommodate any number of conventional spindles that are particularly suited to extend between inwardly facing surfaces of a top and bottom rail. For example, although not illustrated in FIG. 5, a vast number of conventional spindles have an ornate turned configuration in the middle portion thereof, and such spindles are generally only used between inwardly facing surfaces of rails. With prior art conventional rail systems, the ends of such spindles are nailed or screwed to the inwardly facing rail surfaces and face or side boards are then nailed to the top and bottom rails to give the rail a “finished” appearance. However, this construction defines a generally U-shaped channel along the rails that is a favorite nesting place for insects, including wasps, bees, and the like. Also, this configuration does not prevent the spindles from twisting or bowing relative to the rails, and requires additional materials and labor. The embodiment of FIG. 5 is relatively simple yet provides a professional finished appearance to the rail system that is maintained over a longer period of time due to the fact that the spindles are prevented from twisting or turning relative to the rails. 
     It should be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For example, the recesses defined in the rails may take on any shape sufficient for preventing the spindles from twisting or turning relative to the rails. It is intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents.