Patent Publication Number: US-2022220766-A1

Title: Safety rail mounting bracket system

Description:
BACKGROUND OF THE INVENTION 
     1) Field of the Invention 
     The present invention relates to safety rails, and more particularly, to a safety rail mounting bracket system having a first rail holder and a second rail holder for mounting on opposite sides of an opening and each having a base plate carrying two mounting brackets appropriately spaced apart in compliance with regulatory requirements to facilitate the installation and removal of safety railing on a construction site. 
     2) Description of Related Art 
     At construction sites there is a regulatory requirement that a safety railing be present in certain locations to protect workers. The safety railing is a standard railing having a top rail, intermediate rail, and posts carrying the rails, with regulatory requirements defining the height of the rails to each other and to the floor, platform, runway, or ramp level. Typically, these railings are for openings such as windows, balconies and the like. During the construction, the safety rails may be temporarily affixed, such as by nailing or screwing, to the structure. Alternatively, the safety rail may be positioned on standalone posts as the circumstances require. The ones that are attached to the structure are often required to be periodically removed when access to the opening is needed. Repeated attachment to the structure, however, can result in damage to the structure walls around the opening being blocked. The standalone versions require considerably more construction and can impede the area in front of the opening but are typically secured to the structure flooring. Thus, in either case, removal of the railing for temporary access is problematic as it requires deconstructing at least a portion of the railing or its attachment to the structure walls or flooring. 
     Accordingly, it is an object of the present invention to provide a safety rail mounting bracket system with predefined spacing between a top rail and an intermediate rail in compliance with regulatory requirements that releasably carries the rail members for easy removal and installation. 
     It is a further object of the present invention to provide a safety rail mounting bracket system with a first rail holder and a second rail holder for mounting on opposite sides of an opening and each having a base plate that spaces the height of mounting brackets for receiving rail members at a predefined height from the floor in compliance with regulatory requirements. 
     It is a further object of the present invention to provide a safety rail mounting bracket system with a first rail holder and a second rail holder mountable to the sidewalls around an opening that each include mounting brackets for easy insertion and removal of railing members and which meets load bearing regulatory requirements. 
     It is a further object of the present invention to provide a safety rail mounting bracket system that allows for the installation of a first rail holder and a second rail holder to carry rail members at a predetermined height from the floor without the need to measure spacing between the rail members or the height of the rail members from the floor during installation of the first and second rail holders. 
     SUMMARY OF THE INVENTION 
     The above objectives are accomplished according to the present invention by providing a rail holder for a safety rail mounting bracket system comprising an elongated rectangular base plate for mounting in a vertically extending orientation on a mounting surface; an upper mounting bracket carried on a top side of the base plate for releasably carrying a distal end portion of a first rail member; a lower mounting bracket carried on the top side of the base plate for releasably carrying a distal end portion of a second rail member, wherein the lower mounting bracket is vertically spaced from and vertically aligned with the upper mounting bracket; the upper and lower mounting brackets defined by a series of bracket walls having a generally U-shaped arrangement, wherein the bracket walls include a pair of laterally spaced opposing straight side walls vertically aligned on the base plate and an interconnecting straight bottom wall extending between the side walls so that an open top side and an open front side is formed in each the mounting bracket for receiving the first and second rail members along an interior side of the U-shaped walls; and, a series of bracket reinforcing walls laterally spaced from each other and extending outwardly from an exterior side of the bracket walls; whereby the mounting brackets are space apart a predetermined distance on the base plate to comply with applicable regulatory requirements for safety rail installation when mounted to the mounting surface. 
     In a further advantageous embodiment, the base plate includes a floor extension portion extending from below the lower mounting bracket, wherein the floor extension portion engages a floor surface to position the upper and lower mounting brackets at a predetermined height from the floor surface. 
     In a further advantageous embodiment, an angled end portion is included on a distal end of each of the bracket side walls extending outwardly from the open top side to flare the open top side for receiving the rail members between the bracket side walls. 
     In a further advantageous embodiment, a series of fastener openings extend through the base plate for receiving a fastener to secure the base plate to the mounting surface. 
     In a further advantageous embodiment, an upper fastener opening is disposed generally adjacent the open top side between the bracket side walls for each the upper and lower mounting brackets, and a lower fastener opening disposed below the bottom wall of each the upper and lower mounting brackets. 
     In a further advantageous embodiment, each the upper and lower fastener opening includes a counter sink recess for receiving the head of a fastener so that the fastener is flush with the top side of the base plate to avoid interference with the rail members. 
     In a further advantageous embodiment, the bracket reinforcing walls are right-angle triangle shaped walls with the right-angle side disposed adjacent the bracket walls and the hypotenuse side extending from the edge of the bracket walls to the base plate. 
     In a further advantageous embodiment, the base plate includes a recessed interior cavity on a bottom side for facing the mounting surface. 
     In a further advantageous embodiment, a series of base reinforcing walls extend laterally across the recessed interior cavity of the base plate from a first side wall to a second side wall of the base plate. 
     In a further advantageous embodiment, a majority of the base reinforcing walls are concentrated opposite the upper and lower mounting brackets. 
     In a further advantageous embodiment, a series of angled base reinforcing walls extend from a cylindrical fastener opening wall defining the fastener openings in the base plate to the side walls of the base plate. 
     In a further advantageous embodiment, a center reinforcing wall extends between cylindrical fastener opening walls opposite each the upper and lower mounting bracket and extending through the series of laterally extending base reinforcing walls. 
     The above objectives are further accomplished according to the present invention by providing a rail holder for a safety rail mounting bracket system comprising an elongated rectangular base plate for mounting in a vertically extending orientation on a mounting surface; an upper mounting bracket carried on a top side of the base plate for releasably carrying a distal end portion of a first rail member; a lower mounting bracket carried on the top side of the base plate for releasably carrying a distal end portion of a second rail member, wherein the lower mounting bracket is vertically spaced from and vertically aligned with the upper mounting bracket; the upper and lower mounting brackets defined by a series of bracket walls having a generally U-shaped arrangement, wherein the bracket walls include a pair of laterally spaced opposing straight side walls vertically aligned on the base plate and an interconnecting straight bottom wall extending between the side walls so that an open top side and an open front side is formed in each the mounting bracket for receiving the first and second rail members along an interior side of the U-shaped walls; a series of bracket reinforcing walls laterally spaced from each other and extending outwardly from an exterior side of the bracket walls; and, a floor extension portion included in the base plate that extends from below the lower mounting bracket, wherein the floor extension portion engages a floor surface to position the upper and lower mounting brackets at a predetermined height from the floor surface; whereby the mounting brackets are space apart a predetermined distance on the base plate and positioned at a predetermined height from the floor to comply with applicable regulatory requirements for safety rail installation when mounted to the mounting surface. 
     In a further advantageous embodiment, an angled end portion is included on a distal end of each of the bracket side walls extending outwardly from the open top side to flare the open top side for receiving the rail members between the bracket side walls. 
     In a further advantageous embodiment, the bracket reinforcing walls are right-angle triangle shaped walls with the right-angle side disposed adjacent the bracket walls and the hypotenuse side extending from the edge of the bracket walls to the base plate. 
     In a further advantageous embodiment, the base plate includes a recessed interior cavity on a bottom side for facing the mounting surface; a series of base reinforcing walls extending laterally across the recessed interior cavity of the base plate from a first side wall to a second side wall of the base plate; a series of angled base reinforcing walls extending from a cylindrical fastener opening wall defining each the fastener openings in the base plate to the side walls of the base plate; a center reinforcing wall extending between cylindrical fastener opening walls opposite each the upper and lower mounting bracket and extending through the series of laterally extending base reinforcing walls, and; wherein a majority of the base reinforcing walls are concentrated opposite the upper and lower mounting brackets. 
     The above objectives are further accomplished according to the present invention by providing a safety rail mounting bracket system comprising a first rail holder having a first elongated rectangular base plate for mounting in a vertically extending orientation; the first base plate carrying an upper mounting bracket on a top side of the base plate for releasably carrying a first distal end portion of a first rail member, and a lower mounting bracket carried on the top side of the plate for releasably carrying a first distal end portion of a second rail member, wherein the lower mounting bracket is vertically spaced from and vertically aligned with the upper mounting bracket; a second rail holder having a second elongated rectangular base plate for mounting in a vertically extending orientation; the second base plate carrying an upper mounting bracket on a top side of the base plate for releasably carrying a second distal end portion of a first rail member, and a lower mounting bracket carried on the top side of the base plate for releasably carrying a second distal end portion of a second rail member, wherein the lower mounting bracket is vertically spaced from and vertically aligned with the upper mounting bracket; wherein the first base plate is mounted to a first wall defining a first side of an opening and the second base plate is mounted to a second wall opposite the first wall and defining a second side of the opening; and, wherein the first distal end portion of the first rail member is received into the upper mounting bracket on the first base plate, the second distal end portion of the first rail member is received into the upper mounting bracket on the second base plate, the first distal end portion of the second rail member is received into the lower mounting bracket on the first base plate, and the second distal end portion of the second rail member is received into the lower mounting bracket on the second base plate; whereby the mounting brackets on the first and second base plates are space apart a predetermined distance to comply with applicable regulatory requirements so that the first and second rail members are properly positioned within the opening. 
     In a further advantageous embodiment, the upper and lower mounting brackets carried on the first and second base plates are defined by a series of bracket walls having a generally U-shaped arrangement, wherein the bracket walls include a pair of laterally spaced opposing straight side walls vertically aligned on the base plates and an interconnecting straight bottom wall extending between the side walls on each of the base plates so that an open top side and an open front side is formed in each the mounting bracket for receiving the first and second rail members along an interior side of the U-shaped walls. 
     In a further advantageous embodiment, a series of bracket reinforcing walls are laterally spaced from each other and extending outwardly from an exterior side of the bracket walls. 
     In a further advantageous embodiment, a floor extension portion is included in the first and second base plates that extends from below the lower mounting bracket on each of the base plates, wherein the floor extension portion engages a floor surface to position the upper and lower mounting brackets of the first and second base plates at a predetermined height from the floor surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The system designed to carry out the invention will hereinafter be described, together with other features thereof. The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein: 
         FIG. 1  shows a perspective view of a rail holder of the mounting bracket system according to the present invention; 
         FIG. 2  shows a front elevation view of a rail holder of the mounting bracket system according to the present invention; 
         FIG. 3  shows a side elevation view of a rail holder of the mounting bracket system according to the present invention; 
         FIG. 4  shows a rear elevation view of a rail holder of the mounting bracket system according to the present invention; 
         FIG. 5  is a cross-section view along section line A-A of the rail holder of the mounting bracket system shown in  FIG. 2  according to the present invention; 
         FIG. 6  shows a side elevation view of a further embodiment of a rail holder of the mounting bracket system according to the present invention; and, 
         FIG. 7  shows a side elevation view of the mounting bracket system installed in an opening according to the present invention. 
     
    
    
     It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can meet certain other objectives. Each objective may not apply equally, in all its respects, to every aspect of this invention. As such, the preceding objects can be viewed in the alternative with respect to any one aspect of this invention. These and other objects and features of the invention will become more fully apparent when the following detailed description is read in conjunction with the accompanying figures and examples. However, it is to be understood that both the foregoing summary of the invention and the following detailed description are of a preferred embodiment and not restrictive of the invention or other alternate embodiments of the invention. In particular, while the invention is described herein with reference to a number of specific embodiments, it will be appreciated that the description is illustrative of the invention and is not constructed as limiting of the invention. Various modifications and applications may occur to those who are skilled in the art, without departing from the spirit and the scope of the invention, as described by the appended claims. Likewise, other objects, features, benefits and advantages of the present invention will be apparent from this summary and certain embodiments described below, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above in conjunction with the accompanying examples, data, figures and all reasonable inferences to be drawn therefrom, alone or with consideration of the references incorporated herein. 
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     With reference to the drawings, the invention will now be described in more detail. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are herein described. 
     Unless specifically stated, terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. 
     Furthermore, although items, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. 
     Referring to  FIG. 1-7 , a safety rail mounting bracket system is shown. In the illustrated embodiment, the safety rail mounting bracket system includes a first rail holder, designated generally as  10 , that has a first base plate  12  carrying two reinforced mounting brackets  14   a  and  14   b . Mounting brackets  14   a  and  14   b  are spaced apart on base plate  12  such that railing members  20   a  and  20   b  ( FIG. 7 ) carried by the mounting brackets  14   a  and  14   b  are vertically separated at specific predefined distances according to applicable regulatory requirements for the installation of safety railing at a construction site. 
     Referring to  FIG. 7 , in use, the safety rail mounting bracket system includes a second rail holder, designated generally as  11 . Second rail holder  11  is identical to first rail holder  10  and includes a second base plate  16  carrying two reinforced mounting brackets  18   a  and  18   b  vertically spaced apart in compliance with application regulations. Mounting brackets  18   a  and  18   b  are spaced apart on base plate  16  such that railing members  20   a  and  20   b  ( FIG. 7 ) carried by the mounting brackets  18   a  and  18   b  are vertically separated at specific predefined distances according to applicable regulations for safety railing on a construction site. 
     In the illustrated embodiment, the first base plate  12  is mounted to a first wall  22   a  adjacent a first side of an opening and the second base plate  16  is mounted to a second wall  22   b  adjacent a second side of an opening. Once positioned and secured to the wall, a top rail member  20   a  is received into upper mounting brackets  14   a  and  18   a  on each of the first and second rail holders  10 ,  11 , and an intermediate rail member  20   b  is received into lower mounting brackets  14   b  and  18   b  on each of the first and second rail holders  10 ,  11 , to facilitate the installation of safety railing on a construction site in compliance with applicable regulations and without the need to measure the spacing between railings, or as with the embodiments shown in  FIGS. 6 and 7 , without even having to measure the height of the railing members from the floor  24 . 
     In the embodiment of  FIGS. 6 and 7 , the base plates  12 ,  16  carrying the two mounting brackets  14   a ,  14   b ,  18   a ,  18   b , include a floor extension portion  26  below the lower mounter bracket  14   b ,  18   b . The floor extension portion  26  spaces the mounting brackets at a predefined height from the floor  24  when placed against the walls  22   a ,  22   b  around an opening such that the base plate  12 ,  16  extends from the floor  24  up the wall  22   a ,  22   b  to easily position the mounting brackets  14   a ,  14   b ,  18   a ,  18   b  at a height in compliance applicable regulations without the need to measure, thus avoiding the potential for installation errors. The base plates  12 ,  16  are then secured to the walls  22   a ,  22   b  and railing members  20   a ,  20   b  can then be easily inserted and removed from the mounting brackets  14   a ,  14   b ,  18   a ,  18   b  as needed without damaging the wall from repeated installation and removal. 
     In the illustrated embodiment, the mounting bracket system is constructed and arranged to position the top side of the top railing member  20   a  at 42 inches from the floor  24 , and the intermediate railing member  20   b  at 21 inches from floor. The mounting brackets  14   a ,  14   b ,  18   a ,  18   b  are vertically spaced on base plates  12 ,  16  to provide a spacing between railing members of 21 inches from a top side of the upper railing member  20   a  to a top side of the intermediate railing member  20   b . When access to the opening is needed, at least one of the railing members  20   a ,  20   b  is simply removed by lifting the railing member up and out of the mounting bracket, an object placed through the opening, and the railing members simply replaced. 
     Referring to  FIGS. 1-5 , the first and second base plates  12 ,  16  and upper and lower mounting brackets  14   a ,  14   b ,  18   a ,  18   b  for being positioned on opposite sides of an opening are identical in construction. As such, only a first rail holder  10  is shown in  FIGS. 1-5  with the understanding that the illustrated embodiment and description provided herein applies equally to the second rail holder  11  to be positioned on an opposite side of an opening from first rail holder  10  as shown in  FIG. 7 . The same is also true of the embodiment shown in  FIGS. 6 and 7  wherein the base plates  12 ,  16  include floor extension portion  26 . In this embodiment of  FIGS. 1-5 , the base plate  12  does not include the floor extension portion, and thus a single measurement is required to locate the upper or lower mounting bracket  14   a ,  14   b  at the required height above the floor. 
     In the illustrated embodiment of  FIGS. 1-5 , rail holder  10  is shown for one side of the mounting bracket system. In example embodiment, base plate  12  is an elongated rectangular base plate for mounting in a vertically extending orientation on a mounting surface such as a wall. Upper mounting bracket  14   a  is carried on a top side of base plate  12  for releasably carrying a distal end portion of a first rail member  20   a  ( FIG. 7 ). Lower mounting bracket  14   b  is carried on the top side of base plate  12  for releasably carrying a distal end portion of a second rail member  20   b  ( FIG. 7 ), wherein lower mounting bracket  14   b  is vertically spaced from and vertically aligned with upper mounting bracket  14   a.    
     Upper and lower mounting brackets  14   a ,  14   b ,  18   a ,  18   b  are defined by a series of bracket walls having a generally U-shaped arrangement, wherein the bracket walls include a pair of laterally spaced opposing straight side walls  28   a  and  28   b  vertically aligned on base plate  12  and an interconnecting straight bottom wall  28   c  extending between side walls  28   a  and  28   b  so that an open top side  29  and an open front side  31  are formed in each of mounting brackets  14   a ,  14   b  for receiving first and second rail members  20   a ,  20   b  along an interior side of the U-shaped wall arrangement. The bracket side walls  28   a  and  28   b  are spaced to receive a standard 2×4 piece of lumber to operate as a railing member  20   a ,  20   b . The 2×4 can be affixed to the mounting bracket (e.g. pin, screws, etc.) or can be otherwise removably attached to the mounting bracket. For regulatory compliance, (1) the wood railing members  20   a ,  20   b  are minimum 1500 lb-ft/in (2) fiber (stress grade) construction grade lumber, preferably at least 2-inch by 4-inch (5 cm×10 cm) lumber. A center post may be required for openings more than 8 feet (2.4 m) apart. In a preferred embodiment, the top railing member  20   a  is 2-inch by 4-inch (5 cm×10 cm) lumber, while the intermediate railing member  20   b  is at least 1-inch by 6-inch (2.5 cm×15 cm) lumber. All lumber dimensions are nominal sizes as provided by the American Softwood Lumber Standards, dated January 1970. 
     In the illustrated embodiment, a series of bracket reinforcing walls  30  are laterally spaced from each other and extend outwardly from an exterior side of bracket walls  28   a ,  28   b ,  28   c . In the example embodiment, bracket reinforcing walls  30  are shaped as right-angle triangles laterally spaced around the perimeter of the bracket walls. The right-angle side is disposed adjacent the bracket walls  28   a ,  28   b ,  28   c  and the hypotenuse side extends from the edge of the bracket walls down to base plate  12 . 
     As best shown in  FIG. 2 , an angled end portion  32  is includes on a distal end of bracket side walls  28   a  and  28   b . Angled end portions  32  cooperate to flare and expand the entry opening of the open top side  29  of the U-shaped slot defined by the side and bottom bracket walls  28   a ,  28   b ,  28   c  to more easily receive the railing members  20   a ,  20   b.    
     To facilitate securing the base plate  12 ,  16  to a wall, fastener openings  34   a ,  34   b  extend through the base plate  12  at various location along the base plate  12  for receiving a fastener such as a screw, nail, pin and the like. In the illustrated embodiment, as best shown in  FIG. 5 , fastener openings  34   a ,  34   b  include a recess area  36  for counter sinking the securing member to be flush with the surface of the base plate to avoid interference with the rail members. In the example embodiment, an upper fastener opening  34   a  is disposed generally adjacent the open top side  29  between bracket side walls  28   a ,  28   b  for each of the upper and lower mounting brackets  14   a ,  14   b , and a lower fastener opening  34   b  is disposed below bottom wall  28   c  of each of the upper and lower mounting brackets  14   a ,  14   b.    
     Referring to  FIG. 4 , a rear side of base plate  12 ,  16  is shown having a recessed interior cavity  38  on a bottom side for facing the mounting surface. To resist twisting and warping of the base plate, cavity  38  includes a series of base reinforcing walls  40 , with a majority of the base reinforcing walls  40  disposed opposite the mounting brackets  14   a ,  14   b ,  18   a ,  18   b . In the example embodiment, a series of base reinforcing walls  40  extend laterally across recessed interior cavity  38  of base plate  12  from a first side wall to a second side wall of the base plate. Also, a series of angled base reinforcing walls  41  extend from a cylindrical fastener opening wall  45  defining the fastener openings  34   a ,  34   b  in base plate  12  to the side walls of the base plate. Further, a center reinforcing wall  43  extends between cylindrical fastener opening walls  45  opposite each of the upper and lower mounting brackets and extending through the series of laterally extending base reinforcing walls  40 . 
     Accordingly, with proper lumber for the top and intermedia railing members  20   a ,  20   b , the safety rail mounting bracket system of the present invention is capable of withstanding, without failure, a force of at least 200 pounds (890 N) applied within 2 inches (5.1 cm) of the top edge, in any outward or downward direction, at any point along the top edge. Additionally, when the 200 pound (890 N) test load is applied in a downward direction, the top edge of the guardrail does not deflect to a height less than 39 inches (1.0 m) above the walking/working level. Further, mid-rails, screens, mesh, intermediate vertical members, solid panels, and equivalent structural members may be applied as part of the safety rail mounting bracket system and are capable of withstanding, without failure, a force of at least 150 pounds (666 N) applied in any downward or outward direction at any point along the intermediate rail or other member if constructed and arranged according to the present invention. 
     According to the present invention, the upper mounting bracket and the lower mounting bracket  14   a ,  14   b ,  18   a ,  18   b  are carried on the base plate  12 ,  16  so that a certain distance between the floor and the lower mounting bracket and the lower mounting bracket to the top mounting bracket can be easily defined so that the safety railing can comply with the regulations with minimal to no measurements during installation for reducing errors. 
     While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein.