Patent Publication Number: US-10309091-B2

Title: Deck railing assembly

Description:
BACKGROUND 
     Decks are platforms that extend off the sides of buildings. Typically, decks include a frame, decking that is supported by the frame and provides a floor, and railings that enclose the decking and protect people from falling off the deck. The railings include posts that are connected to and extend upward from the frame, top and bottom rails that extend between the posts and in-fills that extend between the top and bottom rails. There are many different types of in-fills including glass, woven meshes, and pickets or balusters. 
     The posts must be adequately secured to the frame to withstand the application of several hundred pounds of lateral force. The in-fills must be such that they prevent children from passing between the top and bottom rails. 
     The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the background. 
     SUMMARY 
     A deck includes a railing formed of a hollow post and a peg that is press fit into the interior of the hollow post. A frame member has at least one hole passing from an exterior of the frame member to an interior of the frame member, wherein the peg is inserted in the hole and is secured to the frame member through frictional contact with surfaces on the interior of the frame member. 
     In a further embodiment, a deck includes a first hollow post comprising a first wall with an opening from an interior of the first hollow post to an exterior of the first hollow post and a second hollow post comprising a second wall with an opening from an interior of the second hollow post to an exterior of the second hollow post. A bottom rail has a first notch at a first end and a second notch at a second end, wherein the first end is inserted in the opening of the first wall such that a portion of the first wall is in the first notch and the second end is inserted in the opening of the second wall such that a portion of the second wall is in the second notch. 
     In a still further embodiment, a deck includes a front top rail connected to a corner post and a side top rail connected to the corner post. A front rail cap is positioned over and connected to the front top rail and has an end positioned over the corner post. A side rail cap is positioned over and connected to the side top rail and has an end positioned over the corner post. A member is positioned between and separates the end of the front rail cap from the end of the side rail cap over the corner post. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a deck in accordance with one embodiment. 
         FIG. 2  is a partially exploded perspective view of the deck of  FIG. 1 . 
         FIG. 3  is a front view of post  140 . 
         FIG. 4  is a bottom view of post  140 . 
         FIG. 5  is a sectional view of a portion of post  140 . 
         FIG. 6  is a top view of post  140  of  FIG. 3 . 
         FIG. 7  is a top view of post  140  with the top rails removed. 
         FIG. 8  is an enlarged view of the front left corner of the frame of the deck of  FIG. 1 . 
         FIG. 9  is a sectional view of a portion of the deck showing the connections between the front header and a beam. 
         FIG. 10  is a side sectional view of a railing in accordance with one embodiment. 
         FIG. 11  is a perspective view showing a bottom rail disengaged from a post. 
         FIG. 12  is a front sectional view of a portion of a post showing a bottom rail engaged with the post. 
         FIG. 13  is a top view of a corner where two rail caps come together. 
         FIG. 14  is a perspective view of the corner of  FIG. 13 . 
         FIG. 15  is a front view of a member placed between two rail caps. 
     
    
    
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     The embodiments described below provide an aluminum deck that can be constructed without welding. In accordance with one embodiment, posts are formed of hollow extruded aluminum and are connected to the frame by an aluminum peg that is hydraulically driven into the hollow post to secure the peg through a friction fit with the interior of the hollow post. The peg is then inserted into a hollow frame member and bolts are used to flex the hollow frame member so that the frame member holds the peg in place. In further embodiments, each hollow post includes interior members that define four channels within the interior of the hollow post. The ends of these four channels can accept and secure a bolt that is screwed into the members that define the channels. These channels are used to secure the top rail to each post by passing a bolt through a top of the top rail and into one of the four channels. In some embodiments, the interior members define open channels and the peg is shaped so that portions of the peg fit into and extend out of each of the four open channels of the post. 
     In still further embodiments, the top and bottom rails provide a system that allows for in-fills to be removed and replaced whenever necessary. In the embodiments, the top rail has an interior and an open bottom and the bottom rail has an interior and an open top. The bottom rail is inserted into holes in the posts such that the bottom rail hangs on the posts without requiring a fastener. The bottom of an in-fill is inserted into the open top of the bottom rail and then the top rail is positioned over the in-fill such that the top of the in-fill extends through the open bottom of the top rail and into the interior of the top rail. The top rail is then secured to the tops of the posts using removable bolts to lock the in-fill in place. By removing the bolts that secure the top rail from the posts, the top rail and the in-fill can be removed and a new in-fill can be inserted into the bottom rail. The top rail can then be reattached to the posts. Thus, the assembly allows in-fills to be replaced without requiring the entire railing to be replaced. 
     In some embodiments, picket in-fills are constructed by cutting groves into the top and bottom of each picket and then capturing the tops and bottoms of the pickets in respective mesh-capture rails. The mesh-capture rails are then inserted into the interiors of the top and bottom rails. 
     In still further embodiments, a rail cap is placed over the top rail to provide a smooth surface and to hide the bolts that attaches the top rail to the posts. The ends of the rail caps are cut at 45 degree angles to form corners where two rails come together. To reduce exposed sharp edges at these corners, a flat member is inserted between the two rail caps at each corner. The flat member extends outside of the outer surface of the rail caps and rests on top of the posts. In some embodiments, the flat member includes a center tongue that is bent under one of the top rails to secure the flat member in place. 
       FIG. 1  provides a perspective view and  FIG. 2  provides a partially exploded perspective view of a deck  100  in accordance with one embodiment. Deck  100  includes a frame  102  consisting of frame members such as front header  104 , back header  106  and side beams  108  and  110 . Front header  104  and side beams  108  and  110  are covered with respective fascia pieces  112 ,  114  and  116 , which snap onto the outer surfaces of front header  104  and side beams  108  and  110  without requiring welding or fasteners. In particular, fascia pieces  112 ,  114  and  116  include vertical portions that cover the outward facing surfaces of front header  104  and side beams  108  and  110  and top and bottom lateral surfaces that have inwardly extending nubs that snap into respective top and bottom groves that extend along the lengths of front header  104  and side beams  108  and  110 . In some embodiments, fascia pieces  112 ,  114  and  116  are painted aluminum pieces and may be removed at any time and replaced with different color fascia pieces. 
     Frame  102  supports deck  118 , which hangs from the edges of frame members  104 ,  106 ,  108  and  110 . In particular, deck support pieces hang from each of the frame members and interconnected decking members are supported by the deck support pieces. The deck support pieces and the decking members are not welded together and any of the deck support pieces or decking member may be lifted out of the frame members and replaced if damaged. 
     Deck  100  also includes two side railings  120 ,  122  and a front railing  124 . Side railing  120  includes post  126 , top rail  128 , bottom rail  130  and in-fill  132  in the form of a plurality of pickets. Side railing  122  includes post  133 , top rail  134 , bottom rail  136  and in-fill  138  in the form of a plurality of pickets. Front railing  124  includes posts  140 ,  142  and  144 , top rail  146  and bottom rails  148  and  150 . In addition, front railing  124  includes first in-fill  152  and second in-fill  154 , which are both constructed of a plurality of pickets. Deck  100  also includes side rail caps  160  and  162  and front rail cap  164 . 
     Each of posts  126 ,  133 ,  140 ,  142  and  144  include a respective peg such as peg  170  of post  126  and peg  300  of post  140 , that fit within respective holes in a frame member such as hole  174  of side beam  108  and hole  810  of front header  104 . 
       FIG. 3  provides a front view of post  140  separate from railing  146  and  148 , but connected to side top rail  128 .  FIG. 4  provides a bottom view of post  140  of  FIG. 3 . Post  140  is shown to include hollow extruded post  302  and solid peg  300 . Hollow post  302  includes four walls  400 ,  402 ,  404  and  406 . Although hollow post  302  is shown as being square in  FIGS. 3  and  4 , in other embodiments, hollow post  302  can take other shapes such as round. Four members  408 ,  410 ,  412  and  414  extend toward the interior of hollow post  302  from respective ones of the four walls. The four members each define a respective channel  306 ,  308 ,  310  and  312 . In particular, each member  400 ,  402 ,  404 , and  406  is constructed of two arms that together with a portion of walls  400 ,  402 ,  404  and  406  form a channel having an open side, such as open side  418  of channel  308 . 
     Channels  306 ,  308 ,  310 , and  312  are shown to be c-shaped in  FIG. 4  and are each capable of receiving a threaded bolt at the top of post  140  such that as a threaded bolt is turned within one of the channels, the threads on the bolt cut into the member that defines the channel thereby securing the bolt to the member. 
     Peg  300  is shown to be a solid peg that has a substantially circular shape with notches cut into it to form tabs  314 ,  316 ,  318  and  320  that fit into channels  306 ,  308 ,  310  and  312  and extend out of the open sides of channels  306 ,  308 ,  310  and  312 . Peg  300  and tabs  314 ,  316 ,  318  and  320  are sized to form a friction fit with members  400 ,  402 ,  404  and  406 . In accordance with one embodiment, the dimensions of the peg relative to hollow extruded post  302  are such that a hydraulic press is required to press fit peg  300  into hollow extruded post  302  during which members  400 ,  402 ,  404  and  406  and/or peg  300  are compressed resulting in a tight fit between peg  300  and hollow extruded post  302 .  FIG. 5  shows a sectional view of the portion of post  140  showing the position of peg  300  within hollow post  302 . 
       FIG. 6  shows a top view of post  140  showing top rail  128  attached to post  140  and top rail  146  shown in phantom. Top rail  128  is attached to post  140  through a bolt  600  that passes into channel  312  and engages with member  414  to secure bolt  600  to post  140 . Top rail  146  is attached to post  140  through a bolt  602  (shown in phantom) that passes into channel  314  and engages with member  408  to secure bolt  602  to post  140 .  FIG. 7  shows a top view of post  140  without top rails  128  and  146 . 
       FIG. 8  provides an enlarged view of the front left corner of frame  102  showing the connection between front header  104  and side beam  108 . As shown in  FIG. 8 , front header  104  is a hollow extruded rectangular shape that includes four channels  820 ,  822 ,  824  and  826  that are defined by four respective members that extend along the length of header  104  and that are shaped to receive bolts such as bolts  812 ,  814 ,  816  and  818  for mounting a screw boss  800  to the end of header  104 . Screw boss  800  can be used to support the front of deck  100 , using a turnbuckle attached to the building. 
     In the embodiment of  FIG. 8 , beam  108  has the exact same structure as header  104  and thus also includes four members in its interior that define four respective channels for receiving bolts. In particular, beam  108  receives bolts  802 ,  804 ,  806  and  808 , which pass through holes drilled in header  104 , thread into the members defining that channels in beam  108  and thereby secure header  104  to beam  108 . Header  104  also includes opening  810  that receives peg  300  of post  140  such that bolts  806  and  808  are on one side of peg  300  and bolts  802  and  804  are on the other side of peg  300  and such that bolts  802 ,  804 ,  806 , and  808  are orthogonal to peg  300 . 
       FIG. 9  shows a sectional view of the connection between header  104  and beam  108  as shown by lines  9 - 9  in  FIG. 2 . In  FIG. 9 , bolts  806  and  808  are shown passing through the interior of beam  104  and into channels  920  and  922  defined by members  924  and  926  of beam  108 . As bolts  806  and  808  are screwed into channels  920  and  922 , threads on bolts  806  and  808  cut into members  924  and  926  resulting in the heads of bolts  806  and  808  applying a force to the sides of header  104 . This force causes header  104  to flex together such that the members that define channels  820 ,  822 ,  824  and  826  presses against peg  300  to secure peg  300  to header  104 . In addition, bolts  802 ,  804 ,  806 , and  808  prevent peg  300  from moving laterally along the length of header  104 . Thus, bolts  802 ,  804 ,  806 , and  808  not only mount header  104  to beam  108  but also secures peg  300  to header  104  without requiring welding of peg  300  or post  302  to header  104 . Posts  126 ,  133  and  144  are similarly secured to the frame members of deck  100 . 
       FIG. 10  provides a side sectional view of a picket  1000  of infill  152 , bottom rail  148 , top rail  146  and rail cap  164 . Picket  1000  includes grooves  1002 ,  1004 ,  1006  and  1008 . Grooves  1002  and  1004  receive legs  1010  and  1012 , respectively of a mesh capture rail  1014  that runs the length of infill  152 . Mesh capture rail  1014  is constructed of two pieces that are pressed together to place legs  1010  and  1012  within grooves  1002  and  1004 . As the pieces are pressed together, they deform to lock the two pieces in place and to lock a top  1016  of picket  1000  within mesh capture rail  1014 . A similar mesh capture rail  1018  has two legs  1020  and  1022  that are pressed into grooves  1006  and  1008  when the two pieces of mesh capture rail  1018  are pressed and locked together. This locks a bottom  1024  of picket  1000  within mesh capture rail  1018 . 
     Mesh capture rail  1018  is then inserted in an interior of bottom rail  148  through the open top  1050  of bottom rail  148 . Top rail  146  is then placed on top of mesh capture rail  1014  such that mesh capture rail  1014  is positioned in the interior  1052  of top rail  146  through open bottom  1054  of top rail  146 . Cap  164  is then placed over top rail  146  and may be secured to top rail  146  using screws. Although only a single picket is shown in  FIG. 10 , all the pickets shown in each infill  132 ,  138 ,  152  and  154  are similarly captured within mesh captures that are in turn located within a top rail and a bottom rail. 
     Although  FIG. 10  shows a plurality of pickets as the infill for deck  100 , in other embodiments other infills are used such as glass and mesh. When a mess infill is used, the same mesh capture rails shown in  FIG. 10  can be used with the mesh. When glass infills are used, the mesh capture rails are replaced with rubber rails that are secured to the tops and bottoms of the glass and that prevent the glass from moving within the top and bottom rails. 
       FIG. 11  provides a perspective view showing bottom rail  148  disassembled from post  302  and  FIG. 12  shows a sectional view of post  302  with bottom rail  148  assembled onto post  302 . As shown in  FIGS. 11 and 12 , the ends of bottom rail  148  are cut to form two notches  1104  and  1106  that define two downwardly extending legs  1100  and  1102 . Wall  400  of post  302  includes two holes  1110  and  1112  that extend from the exterior of post  302  to the interior of post  302  and that are large enough to accept legs  1100  and  1102 . After legs  1100  and  1102  pass through holes  1110  and  1112 , bottom rail  148  is dropped so that the surfaces defining notches  1104  and  1106  engage with wall  400  of post  302  thereby securing bottom rail  148  to post  302 . Similar legs are found on the other end of bottom rail  148  and are used to mount bottom rail  148  to post  142 . Bottom rails  150 ,  130  and  136  have a similar construction to bottom rail  148 . 
       FIG. 13  shows a top view of a section of deck  100  where rail caps  160  and  164  meet.  FIG. 14  shows a perspective view of the section shown in  FIG. 13 . As shown in  FIGS. 13 and 14 , the ends of rail caps  160  and  164  are cut at 45° angles. In accordance with some embodiments, a flat member  1300  is positioned between the ends of rail caps  160  and  164  and between the ends of top rail  146  and top rail  128  to prevent large gaps from appearing between rail caps  160  and  164 . In accordance with one embodiment, the outer surface  1614  of member  1300  extends above the outer surfaces of rail caps  160  and  164 . 
       FIG. 15  provides a front view of flat member  1300  showing that flat member  1300  includes two legs  1600  and  1602  that include flat bottoms  1604  and  1606  and registration tabs  1608  and  1610 , respectively. Registration tabs  1608  and  1610  are designed to hang over the corners of post  302  and flat surfaces  1604  and  1606  are designed to rest on the top of post  302 . Outer surface  1614  of flat member  1300  has a rounded appearance. Flat member  1300  also includes a tongue  1616  extending down from the middle of a central member  1618 . Tongue  1616  is designed to be bent so that it can be secured under one of top rail  146  or top rail  128 . 
     Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.