Patent Publication Number: US-2006006372-A1

Title: Barrier system with multi-position rail

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This application is a continuation-in-part of U.S. patent application Ser. No. 10/764,333, filed Jan. 23, 2004, entitled “MULTI-POSITION RAIL FOR A BARRIER,” which claimed the benefit of U.S. Provisional Application Ser. No. 60/473,535, filed May 26, 2003, which applications are hereby incorporated by reference herein in their entireties, including but not limited to those portions that specifically appear hereinafter, the incorporation by reference being made with the following exception: In the event that any portion of the above-referenced applications is inconsistent with this application, this application supercedes said above-referenced applications. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
      Not Applicable.  
     BACKGROUND  
      1. The Field of the Invention  
      The present disclosure relates generally to rails, and more particularly, but not exclusively, to rails that can be used in various positions and orientations as part of a barrier system.  
      2. Description of Related Art  
      Rails are known in the art for use in decks, porches, stairs, and fences for example. Such rails are useful in providing a secure barrier and adding to the aesthetic appearance of structures. Rails are commonly used with upright members such as pickets, planks or balusters of various sizes, configurations and spacing. Moreover, rails are often used as support members on the bottom of the barrier and towards the top of the barrier. The configuration of bottom rails is often different than the configuration of top rails. Thus, rails of multiple designs are often required in a single barrier system.  
      Also, it is common to use a particular style of rail with different types of upright members in different settings. Therefore, manufacturing and installation of barrier systems often requires the use of tools and machinery to form the rails to the desired configuration to be compatible with the particular upright members to be used.  
      Rails made of durable materials often have a more attractive appearance, but may be more difficult to cut or otherwise shape into condition for use with a particular upright member. Moreover, cutting of the rails to accommodate the upright members may weaken the rails.  
      The use of a different design for top rails as compared to bottom rails may increase the difficulty in providing proper inventory of barrier components. Also, the need to accommodate upright members of various different shapes and spacings may increase the amount of inventory of components required, and may also increase the difficulty and cost of installing the barrier.  
      The prior art is thus characterized by several disadvantages that are addressed by the present disclosure. The present disclosure minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.  
      The features and advantages of the disclosure will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the disclosure without undue experimentation. The features and advantages of the disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The features and advantages of the disclosure will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which:  
       FIG. 1  is a perspective break-away view of a barrier system of the present disclosure;  
       FIG. 2  is a perspective break-away view of a rail in a first orientation with a cover attached thereto;  
       FIG. 3  is a perspective break-away view of a rail in a second orientation with a cover attached thereto;  
       FIG. 4  is an end view of a rail with a cap attached thereto;  
       FIG. 5  is a perspective break-away view of the rail of  FIG. 4 ;  
       FIG. 6  is a perspective break-away view of an alternative barrier system with the rail of the present disclosure on the bottom, and an alternative rail on the top;  
       FIG. 7  is a perspective view of a rail in a first orientation with an alternative embodiment cover attached thereto;  
       FIG. 8  is a perspective view of a rail in a second orientation with the alternative embodiment cover of  FIG. 7  attached thereto;  
       FIG. 9  is a perspective view of a rail in a first orientation with a further alternative embodiment cover attached thereto;  
       FIG. 10  is a perspective view of a rail in a second orientation with the alternative embodiment cover of  FIG. 9  attached thereto;  
       FIG. 11  is a perspective view of a rail in a first orientation with an additional alternative embodiment cover attached thereto;  
       FIG. 12  is a perspective view of a rail in a second orientation with the alternative embodiment cover of  FIG. 11  attached thereto;  
       FIG. 13  is a perspective view of a rail in a first orientation with another alternative embodiment cover attached thereto;  
       FIG. 14  is a perspective view of a rail in a second orientation with the alternative embodiment cover of  FIG. 13  attached thereto;  
       FIG. 15  is a perspective break-away view of another alternative embodiment barrier system; and  
       FIG. 16  is an exploded perspective view of a rail, rail cover, and post.  
    
    
     DETAILED DESCRIPTION  
      For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure claimed.  
      It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.  
      In describing and claiming the present disclosure, the following terminology will be used in accordance with the definitions set out below.  
      As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.  
      “Interference fit” as used herein shall refer to the concept of a connection between two members in which a portion of one member abuts some portion of the other member in a manner that contactibly blocks the separation of the two members.  
      Referring now to  FIG. 1 , an exemplary perspective break-away view is shown of a barrier system of the present disclosure, indicated generally at  10 . The barrier system  10  may form a railing system for use with decks, porches, stairs, or walkway, or a fence for use in defining a property boundary, for example.  
      The barrier system  10  may include one or more rails  12  configured to be supported in a laterally extending orientation. The rails  12  may be positioned at an upper portion and at a lower portion of the barrier system  10 . Alternatively, it will also be appreciated that the barrier system  10  may utilize a single rail  12 .  
      The barrier system  10  may also include a boundary-defining barrier means  14 . The boundary-defining barrier means  14  may include upright members such as pickets, planks, balusters, or walls for example, of any of a variety of shapes, sizes and styles, for defining a boundary. In the embodiment of  FIG. 1 , the boundary-defining barrier means  14  extends between the rails  12  to form part of a barrier system  10 . It will be understood that the boundary-defining barrier means  14  may include a plurality of upright members.  
      The barrier system  10  may also include a rail cover  16  for receiving a rail  12 . The rail cover  16  may be positioned on the top of the barrier system  10  and may be shaped in various different styles and configurations to provide an aesthetically pleasing appearance. Examples of some of the various different styles of covers are depicted in  FIGS. 7-14 , designated by reference numerals  16   a - 16   d . The rail cover  16  may also be configured so as to provide a gripping surface such that the rail cover  16  can be grasped to provide support to a person. Also, the rail cover  16  may have an exterior appearance similar to a solid wood rail. The rail cover  16  may cover only a portion of the rail  12  such that part of the rail  12  may remain visible even when the rail cover  16  is attached. Ends of the barrier system  10  may be supported by a structure or post  17 , as shown in  FIG. 16 , for example. It will be appreciated that the certain embodiments of the barrier system  10  may be formed with the rail cover  16 , whereas other embodiments of the barrier system  10  may be formed without the rail cover  16 .  
      Details of the rail  12  will now be explained with particular reference to  FIGS. 2-5 . The rail  12  may include a first side wall  18  forming a first side of the rail  12 , and a second side wall  20  forming a second side of the rail  12 . The rail  12  may also have a cross wall  22  extending between the first side wall  18  and the second side wall  20 . As shown in  FIG. 2 , the cross wall  22  may extend between the first side wall  18  and the second side wall  20  at a top side  24  of the rail  12 . However, it will be appreciated that the rail  12  may be oriented such that the cross wall  22  may be on a bottom side  28  of the rail  12 .  
      The rail  12  may also have one or more brace members  28  extending between the first side wall  18  and the second side wall  20 . The brace member  28  may be a continuous wall or it may be formed as a series of discrete members positioned along the length of the rail  12  to help provide strength to the rail  12 . The brace member  28  may be centrally located between the top side  24  and the bottom side  26  of the rail  12 . However, it will be appreciated that the brace member  28  may be spaced at any distance between the top side  24  and the bottom side  26 , and that any number of brace members  28  may be used.  
      A chamber  30  may be defined by the first side wall  18 , the second side wall  20 , the cross wall  22 , and the brace member  28 . Similarly, a channel  32  may be defined by the first side wall  18 , the second side wall  20 , and the brace member  28 . It will be appreciated that the boundary-defining barrier means  14  may be received in the chamber  30  or the channel  32  as discussed more fully below.  
      The brace member  28  may have one or more ridges  34  for providing support to the brace member  28 , for contacting the boundary-defining barrier means  14 , or for locating and supporting brackets  35 , as shown in  FIG. 16 , for attaching the rail  12  to a post  17  or support structure, for example. The brackets  35  may be formed in any manner known to those skilled in the art and may be attached to the rail  12  with screws or any other variety of fasteners known in the art. The ridges  34  may extend along a length of the brace member  28 . The brace member  28  may also include grooves  36  for locating a center of the brace member  28  for receiving the screws or drill bits for making openings for the screws. The grooves  36  may also extend along the length of the brace member  28 . It will be understood that embodiments of the brace member  28  may be formed without the ridges  34  or grooves  36 , or that the quantity, shape and location of the ridges  34  and grooves  36  may vary within the scope of the present disclosure.  
      In one embodiment, the rail  12  may be formed in a one-piece unitary manner such that the cross wall  22  may be formed integrally with the rail  12  so as to be inseparable from the first side wall  18  and the second side wall  20 . Accordingly, no joints or seams may be formed between the cross wall  22  and the first side wall  18  and the second side wall  20 , or between the brace member  28  and the first side wall  18  and the second side wall  20 , in this embodiment. It will be appreciated that other embodiments of the rail  12  may be constructed in separable components within the scope of the present disclosure.  
      The rail  12  may also include means  38  for engaging with the rail cover  16  to attach the rail  12  to the rail cover  16 . The engaging means  38  may be in the form of protrusions extending away from the rail  12 . In one embodiment, the first side wall  18  and the second side wall  20  may have exterior planar portions  40  and the engaging means  38  may be formed as protrusions that extend beyond the plane defined by the planar portions  40 . The engaging means  38  may be curved and may have a radius defining a rounded configuration. However, it will be appreciated that the engaging means  38  may have various different shapes and configurations within the scope of the present disclosure. The engaging means  38  may be received in the rail cover  16  to form an interference fit to prevent the rail  12  from being pulled out of the rail cover  16 .  
      It will be appreciated that the first side wall  18  and the second side wall  20  may have various different configurations, such as curved or angular shapes, and need not have the planar portions  40 . The rail  12  may be inserted into an end of the rail cover  16  such that the engaging means  38  may be received in receiving means  42  formed in the rail cover  16 . The receiving means  42  may be shaped to abut with the engaging means  38  to hold the rail  12  in place with respect to the rail cover  16 . However, the rail  12  may slide with respect to the rail cover  16  in a direction along a longitudinal axis  44  of the rail  12  to locate the rail  12  in a desired position.  
      Alternatively, it will be appreciated that the rail  12  and/or rail cover  16  may be formed with flexible elastic properties that allow the rail  12  and/or rail cover  16  to deflect. The rail  12  can therefore be inserted into the rail cover  16  along the length of the rail cover  16  rather than at the end of the rail cover  16 . The rail  12  and rail cover  16  may thus be configured to be connected together with a snap fit.  
      The engaging means  38  may be formed on both the top side  24  and the bottom side  26  of the rail  12 . Accordingly, as can be seen by inspection of  FIGS. 2 and 3 , the rail  12  may be attached to the rail cover  16  such that the cross wall  22  may be positioned within the rail cover  16 , as shown in  FIG. 2 . Alternatively, the rail  12  may be rotated by substantially 180 degrees with respect to the rail cover  16 , about the longitudinal axis  44 , such that the channel  32  may be positioned within the rail cover  16 , as shown in  FIG. 3 . In other words, the rail  12  may be placed in a first orientation, as shown in  FIG. 2 , or the rail  12  may be inverted to a second orientation as shown in  FIG. 3 .  
      Attachment of the barrier means  14  to the rail  12  will now be described. The barrier means  14  may be received within the channel  32  as shown in  FIG. 1 . The barrier means  14  may contact the brace member  28  at the ridges  34  to be supported in an upward position. The first side wall  18  and the second side wall  20  may support the barrier means  14  in a lateral direction.  
      To further support the barrier means  14  in a lateral direction along the length of the rail  12 , a cap  46  may be placed over the channel  32  as shown in  FIGS. 4-5 . The cap  46  may have openings  48  for receiving the barrier means  14 . The openings  48  may be formed in the cap  46  by any manner known in the art such as using a router, or punching, stamping or cutting for example. As such, the openings  48  may be placed in the cap  46  during manufacturing of the cap  46 , such that the openings  48  have predetermined spacings, sizes and shapes. Alternatively, the openings  48  may be formed in the cap  46  at the time of assembling the barrier system  10 , such that the spacing, size and shape of the openings  48  can be custom made. Placing the openings  48  in the cap  46  may provide an advantage in that the openings  48  need not be formed in the rail  12 . Forming openings in the rail  12  may weaken the rail  12  when the rail  12  is formed of certain composite materials for example.  
      The cap  46  may be made of any suitable material known in the art such as vinyl, metal, or composite materials, for example. The cap  46  may have attaching means  50  that may include a shaped portion of the cap  46  configured for receiving the engaging means  38 . Thus, the cap  46  may be attached to the rail  12  with an interference fit. The shape of the attaching means  50  may correspond to the shape of the engaging means  38  on the rail  12  to provide an aesthetically pleasing and tight fitting connection that may not create a protruding ledge that may be prone to snagging or accumulating debris. It will be appreciated that other attaching means such as fasteners or adhesives may also be used to attach the cap  46  to the rail  12  within the scope of the present disclosure.  
      Similar to the rail cover  16 , the cap  46  may be attached to the rail  12  by sliding the cap  46  over an end of the rail  12 , or by deflecting the cap  46  to snap the cap  46  onto the rail  12 . The cap  46  may also include ledges  52  to facilitate aligning the cap  46  on the rail  12 , and holding the cap  46  in position with respect to the rail  12 . Moreover, the rail  12  may include slots  54  for receiving an edge portion of the cap  46  so that the connection between the cap  46  and the rail  12  may be more secure and aesthetically pleasing.  
      With the cap  46  secured to the rail  12 , the barrier means  14  may be placed through the openings  48  such that the cap  46  may assist in providing proper spacing and support for the barrier means  14 . The position of the cap  46  may be moved with respect to the rail  12  so that the openings  48  can be positioned as desired and the orientation of the barrier means  14  may be adjusted. Thus, assembly of the barrier system may be facilitated.  
      In an alternative orientation of the rail  12 , as shown in  FIGS. 3, 6 ,  8 ,  10 ,  12 , and  14 , a portion of the barrier means  14  may be received within the chamber  30 . Holes  56  may be formed in the cross wall  22  to accommodate the barrier means  14 , as best shown in  FIG. 6 . Similar to the openings  48  in the cap  46 , the holes  56  may be formed in any manner known in the art, either as the rail  12  is manufactured, or as the barrier system  10  is assembled. Thus, the cross wall  22  may be used to support the barrier means  14  when the rail  12  is oriented with the cross wall  22  in contact with the barrier means  14 . It will be understood that in this orientation, the cap  46  may not be required.  
      Accordingly, the cross wall  22  and the cap  46  may collectively form a supporting means for (i) supporting a first boundary-defining barrier means  14  in position with respect to the rail  12  when the rail  12  is disposed in a first orientation, and (ii) supporting a second boundary-defining barrier means  14  in position with respect to the rail  12  when the rail  12  is disposed in a second orientation, wherein the second orientation is rotated about the longitudinal axis  44  by substantially 180 degrees from the first orientation.  
      It will be appreciated that the rail  12  may be configured to be versatile to be used in various positions and orientations in the barrier system  10  within the scope of the present disclosure. For example, as shown in  FIG. 1 , the rail  12  may be used as part of the top rail and the bottom rail within the barrier system  10 . Moreover, embodiments of the rail  12  may be positioned in a central portion of the barrier system  10 . Various different shapes and styles of rail covers  16  may be accommodated by the rail  12 . An alternative embodiment barrier system  10   a , is shown in  FIG. 6 , in which the rail  12  may be used for only a bottom rail, and a different variety of rail, such as a connection rail or U-rail  58 , may be used for a top rail. Similarly, the rail  12  may be used for only the top rail. Also, the rail  12  may be oriented such that the barrier means  14  may be received in the channel  32 , or in the chamber  30 .  
      In one embodiment, the U-rail  58  may include recesses  60 . The recesses  60  may be configured to receive fasteners for attaching the U-rail  58  to the barrier means  14 . It will be understood that the barrier means  14  may be substantially hollow and may have a central bore extending along a length of the barrier means  14 . The bore may be defined by interior brace structure and the bore may be used for receiving fasteners to attach the U-rail to the barrier means  14 . Alternatively, the barrier means  14  may be solid such that fasteners may be located as desired. The recesses  60  may be located in the top of the U-rail  58  and/or the sides of the U-rail. Accordingly, when a fastener is placed in the recess  60 , the cover  16  may slide over the U-rail  58  without the fastener contacting the cover  16  to interfere with the sliding movement between the cover  16  and the U-rail  58 . It will also be understood that recesses  60  may be formed in the rail  12  in a similar manner.  
      The engaging means  38  may be configured, in one aspect of the disclosure, to provide an aesthetically pleasing appearance. The rail  12  may be formed to be symmetrical, such that the external appearance of the rail  12  may be similar regardless of whether the rail  12  is oriented with the channel  32  on the top, or the cross wall  22  on the top.  
      The components of the barrier system  10  may be formed of various different suitable materials within the scope of the present disclosure. For example, components of the barrier system  10  may be formed of a PVC material, and/or a metal material. Also, the barrier system may be formed of a composite material made from materials such as a blend of wood flour and PVC resin, for example, and the components may have an extruded PVC vinyl top coating. The components of the present disclosure may also be formed of a composite of polypropylene or polyethylene and wood. Some embodiments may include inserts made of metal, such as aluminum, for added strength. Also, the barrier system components may be made from a pultrusion process with fiber reinforced material made from a blend of fiberglass and PVC resin, for example, with an extruded acrylic top coating, or any other suitable material known in the art may also be used to form the components of the barrier system  10 .  
      As used herein, the term “pultrusion” refers to a process for manufacturing reinforced profiles wherein a set of fibers is pulled through a resin bath and then through a heated die giving the profile its shape. After the profile passes through the die the profile may be cooled by air or water and cut into desired lengths. The resin used may be of various materials such as polyesters, vinyl esters, and epoxies for example. Furthermore, various types of fibers may be added in the pultrusion process to produce profiles having different characteristics, such as different strengths, hardnesses, or elasticities. The fiber may be either a fiber mat or a series of continuous fibers, or any other suitable fiber reinforcement. The pultruded fiber reinforced material may provide components having high hardness and strength characteristics and an attractive high quality appearance.  
      Reference will now to made to  FIG. 15  to describe another alternative embodiment barrier system, indicated generally at  10   b . As previously discussed, the presently disclosed embodiments illustrated herein are merely exemplary of the possible embodiments of the disclosure, including that illustrated in  FIG. 15 . It will be appreciated that the alternative embodiment illustrated in  FIG. 15  contains many of the same structures represented in  FIGS. 1-14  and only the new or different structures will be explained to most succinctly explain the features of the embodiment illustrated in  FIG. 15 .  
      The alternative embodiment barrier system  10   b  may include a rail  12   a . The rail  12   a  may include a first side wall  18   a , a second side wall  20   a , and a cross wall  22   a . The first side wall  18   a  and the second side wall  20   a  may be characterized by an absence of protrusions. Moreover, the rail  12   a  may not include openings in the cross wall  22   a , and the rail  12   a  may be utilized without a cap. A cover  16   e  may be configured to receive the rail  12   a , and the rail  12   a  may be oriented in two positions. For example, the rail  12   a  may be oriented such that the cross wall  22   a  is be on the top to form a top rail, or the rail  12   a  may be oriented such that the cross wall  22   a  is on the bottom to form a bottom rail.  
      It will be appreciated that the structure and apparatus disclosed herein is merely one example of a means for engaging (or engaging means), and it should be appreciated that any structure, apparatus or system for engaging which performs functions the same as, or equivalent to, those disclosed herein are intended to fall within the scope of a means for engaging, including those structures, apparatus or systems for engaging which are presently known, or which may become available in the future. Anything which functions the same as, or equivalently to, a means for engaging falls within the scope of this element.  
      Similarly, it will be appreciated that the structures and apparatus disclosed herein are merely exemplary of a boundary-defining barrier means, receiving means, supporting means, and attaching means, and it should be appreciated that any structure, apparatus or system which performs functions the same as, or equivalent to, those disclosed herein are intended to fall within the scope of a boundary-defining barrier means, receiving means, supporting means, or attaching means, including those structures, apparatus or systems which are presently known, or which may become available in the future. Anything which functions the same as, or equivalently to, a boundary-defining barrier means, receiving means, supporting means, and attaching means falls within the scope of these elements, respectively.  
      In accordance with the features and combinations described above, a useful method of forming barriers includes the steps of: 
          (a) providing a plurality of rails each having a longitudinal axis, a channel on one side and a cross wall on an opposing side;     (b) orienting one of the rails in a first orientation and placing a first boundary-defining barrier means in the channel;     (c) orienting another of the rails in a second orientation rotated substantially 180 degrees from the first orientation about the longitudinal axis;     (d) forming at least one hole in the cross wall; and     (e) placing a second boundary-defining barrier means in the hole.        

      Those having ordinary skill in the relevant art will appreciate the advantages provide by the features of the present disclosure. For example, it is a feature of the present disclosure to provide a rail and barrier system that is simple in design and manufacture. Another feature of the present disclosure is to provide such a rail that is versatile to be used in various orientations and positions within the barrier system, such that inventory of barrier system components may be reduced. It is a further feature of the present disclosure, in accordance with one aspect thereof, to provide such a rail that has an aesthetically pleasing appearance and which allows for assembly with or without cutting holes in the rail.  
      In the foregoing Detailed Description, various features of the present disclosure are grouped together in single embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of the foregoing disclosed embodiments. Thus, the following claims are hereby incorporated into this Detailed Description by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.  
      It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present disclosure. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present disclosure and the appended claims are intended to cover such modifications and arrangements. Thus, while the present disclosure has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein.