Patent Publication Number: US-7913960-B1

Title: Bracketing system

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
     Railing systems have been used in various forms to protect and secure people, animals, and land. Railing systems have also been used to prevent entry into a designated area. While these functional railing uses continue today, railing systems may also be used for decorative purposes such as on porches and decks and around yards and gardens. 
     Known railing systems suffer from various drawbacks. For instance, many conventional railing systems are difficult to install, thereby requiring significant amounts of on-site labor. In addition, many railing systems require an excessive number of parts in order to complete an installation. For example, known systems may require different components for perpendicular and angled installations (e.g., relative to a support post). In other words, these systems may require different components for perpendicular installations as compared to the components used for angled installations. In fact, these systems may also require different components for angled installations in which the railing is horizontal as compared to angled installations in which the railing is at a vertical angle relative to a support post (e.g., a stair rail installation). As might be expected, the extra components may increase the complexity and cost of the manufacturing, shipping, and installation of the railing assembly. On the other hand, some existing railing assemblies may not even allow angled installations. Moreover, known railing systems may also fail to provide a desired aesthetic appearance. For example, these railing systems may leave the support hardware exposed, which limits the visual appearance of the product. In light of shortcomings such as these, there is a need for an improved rail system and method of assembly. 
     An exemplary embodiment of the present invention provides a rail system that may be comprised of any material that is suitable for the intended purpose of the railing. For example, the rail system may be comprised of a composite material that is durable and resistant to weathering. In addition, an exemplary embodiment of the rail system may be easily assembled on-site. If desired, the rail system may be at least partially pre-assembled at an off-site location. In one exemplary embodiment, the rail system may be uniquely designed to accommodate perpendicular and angled installations (e.g., both in the horizontal and vertical planes). In another exemplary embodiment, the rail system may be easily assembled such that the support hardware is substantially hidden from view after installation, thereby enhancing the appearance of the railing. In light of such benefits, the present invention may provide an easy to install, weather-resistant, safe, secure, and aesthetically pleasing rail system that is suitable for a variety of indoor and outdoor uses. 
     Another exemplary embodiment of the present invention provides an improved bracketing system. An example of an improved bracketing system may comprise a first portion that is adjustably connected to a second portion. The first portion may pivot, rotate, or otherwise be adjusted relative to the second portion to accommodate perpendicular and angled installations. An exemplary embodiment of a bracketing system may include angled holes to receive fasteners, which may promote ease of installation. An exemplary embodiment of a bracketing system may also provide additional strength when installed. 
     In addition to the novel features and advantages mentioned above, other features and advantages of the present invention will be readily apparent from the following descriptions of the drawings and exemplary embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional view of an exemplary embodiment of a rail of the present invention. 
         FIG. 2  is a cross-sectional view of an exemplary embodiment of a post cover of the present invention. 
         FIGS. 3A through 3K  illustrates the components of an exemplary embodiment of a rail system that may utilize the present invention. 
         FIG. 4  is a partial perspective view of an exemplary embodiment of a rail system using at least some of the components of  FIGS. 3A through 3K . 
         FIG. 5  illustrates various views of the exemplary embodiment of the bracket of  FIG. 3I . 
         FIG. 6  illustrates various views of the exemplary embodiment of the support block of  FIG. 3J . 
         FIG. 7  is a partial, cross-sectional view of an exemplary installation of a rail system using at least some of the components of  FIGS. 3A through 3K . 
         FIG. 8A  is a cross-sectional view of an exemplary embodiment of a baluster of a rail system. 
         FIG. 8B  is a cross-sectional view of an exemplary embodiment of a baluster plug. 
         FIG. 8C  is a cross-sectional view of the baluster of  FIG. 8A  with baluster plug of  FIG. 8B  installed. 
         FIG. 8D  is a cross-sectional view of an exemplary embodiment of a baluster plug with a hole. 
         FIG. 8E  is a cross-sectional view of an exemplary embodiment of a baluster with the baluster plug of  FIG. 8D  installed. 
         FIG. 8F  is cross-sectional view of another exemplary embodiment of a baluster plug with a hole. 
         FIG. 8G  is a cross-sectional view of an exemplary embodiment of a baluster with the baluster plug of  FIG. 8F  installed. 
         FIG. 9  is a partial perspective view of an exemplary embodiment of an installed lower support rail. 
         FIG. 10  is a partial perspective view illustrating an exemplary manner of attaching a bracket to a support rail. 
         FIG. 11  is another partial perspective view of an exemplary embodiment of an installed lower support rail. 
         FIG. 12  is another partial perspective view illustrating an exemplary manner of attaching a bracket to a support rail. 
         FIG. 13  is a partial perspective view of an exemplary manner of attaching a bottom rail and balusters to an upper support rail. 
         FIG. 14  is a partial perspective view of an exemplary manner of attaching a bracket to a support rail for an angled installation of a rail. 
         FIG. 15  is a partial perspective view of an exemplary manner of attaching a bottom rail and balusters to an upper support rail for an angled installation of a rail. 
         FIG. 16  is a partial, cross-sectional view of an exemplary installation of a rail system in a stair rail application. 
         FIG. 17  is a partial perspective view illustrating an exemplary manner of attaching a support block to a post cover in a stair rail installation. 
         FIG. 18  is a partial perspective view illustrating an exemplary manner of attaching a support rail and support block to a post in a stair rail installation. 
         FIG. 19  is a partial perspective view illustrating an exemplary manner of attaching a support rail and bracket to a post in a stair rail installation. 
         FIG. 20  is a partial perspective view illustrating an exemplary installation of a support rail between two posts in a stair rail application. 
         FIGS. 21A through 21H  are partial perspective views illustrating a sequential step-by-step installation of an exemplary embodiment of a handrail system. 
         FIGS. 22A through 22D  are partial perspective views illustrating a sequential step-by-step installation of an exemplary embodiment of a stair rail system. 
         FIG. 22E  is a perspective view of an exemplary embodiment of a system for installing a support block. 
         FIG. 23  illustrates a top view of another embodiment of an exemplary bracketing system. 
         FIG. 24  illustrates a bottom view of the exemplary bracketing system of  FIG. 24 . 
         FIG. 25  is a perspective view of another embodiment of an exemplary bracketing system. 
         FIG. 26  is a perspective view of another embodiment of the bracketing system of  FIG. 25 . 
         FIG. 27  is a perspective view of another embodiment of an exemplary bracketing system. 
         FIG. 28A  is a side elevation view of an exemplary embodiment of a portion of a bracketing system. 
         FIG. 28B  is a top plan view of the exemplary embodiment of the portion of a bracketing system of  FIG. 28A . 
         FIG. 28C  is another side elevation view of the exemplary embodiment of the portion of a bracketing system of  FIG. 28A . 
         FIG. 28D  is a perspective view of the exemplary embodiment of the portion of a bracketing system of  FIG. 28A . 
         FIG. 29A  is a top plan view of an exemplary embodiment of a portion of a bracketing system. 
         FIG. 29B  is a side elevation view of the exemplary embodiment of the portion of a bracketing system of  FIG. 29A . 
         FIG. 29C  is a bottom plan view of the exemplary embodiment of the portion of a bracketing system of  FIG. 29A . 
         FIG. 29D  is another side elevation view of the exemplary embodiment of the portion of a bracketing system of  FIG. 29A . 
         FIG. 29E  is a perspective view of the exemplary embodiment of the portion of a bracketing system of  FIG. 29A . 
         FIG. 30A  is a perspective view of an exemplary installation of a bracketing system. 
         FIG. 30B  is another perspective view of the exemplary installation of a bracketing system. 
         FIGS. 31A through 31D  show various views of an exemplary embodiment of a bracketing system of the present invention. 
         FIGS. 32A through 32E  show various views of an exemplary embodiment of a portion of the bracketing system of  FIGS. 31A through 31D . 
         FIGS. 33A through 33C  show various views of an exemplary embodiment of another portion of the bracketing system of  FIGS. 31A through 31D . 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       FIG. 1  illustrates an example of a component of the present invention. In this example, handrail or top rail  10  (hereinafter generally and collectively referred to as a handrail for ease of description) may be comprised of a composite substrate  12  and a capstock layer  14 . The handrail  10  may, for example, be useful for a deck railing system or other similar or suitable types of railing. 
     Another exemplary component of the present invention is illustrated in  FIG. 2 .  FIG. 2  shows an exemplary rail post cover  20  that also comprises a composite substrate  22  and a capstock layer  24 . Such a cover may be installed, for example, over an existing wood post to provide an aesthetically pleasing appearance as well as to provide protection from exposure to the elements. 
       FIGS. 3A through 22D  show an example of a railing system that may utilize the components shown in  FIGS. 1 and 2 . The novel features of this exemplary embodiment provide an easy method of assembling the rail components to accommodate linear and angled walkways (e.g., decks) as well as stair rail applications that require changes in elevation. 
     In particular, rail  10  and rail  50  may be directly or indirectly connected to post cover  20  at a variety of horizontal and vertical angles, such as for deck and stair applications. Optional post covers  20 , post caps  26 , and post skirts  28  may be installed over pre-installed posts from which they derive structural rigidity and strength. Nevertheless, it should be recognized that the railing may utilize a post without the benefit of the post cover components. 
     In the railing system, balusters  30 A or  30 B extend between an upper support rail  40  and bottom rail  50 .  FIG. 3E  shows an example of a baluster  30 A, which has inner webbing and a screw boss. However, as shown in subsequent figures, exemplary embodiments of the present invention also include baluster configurations that do not have inner webbing. 
     Top rail  10  and bottom rail  50  are fitted over respective support rails  40 . At least one squash block  60  may be installed beneath the lower support rail  40  where desired to provide additional rigidity and support against sagging (e.g., for long spans of railing that extend between post covers  20 ). A squash block  60  may have a design similar to a baluster, and it may have similar means of connection (e.g., via a screw boss or plug) to a support rail  40  as a baluster. 
     Brackets  70  and support blocks  80  provide a means for directly or indirectly attaching the support rails  40  to the post covers  20 . Optionally, fasteners  90  may be used to secure brackets  70  and support blocks  80  to post covers  20  and support rails  40 . It should be noted that  FIG. 3K  shows various sizes of fasteners, which are collectively identified as fasteners  90 . An appropriate size of fastener  90  may be selected for each intended use. Examples of fasteners  90  include, but are not limited to, screws, nails, and other similar or suitable mechanical fastening devices. In some embodiments of the railing, other means (e.g., adhesives or a suitable interference fit) may be used alone or in combination with fasteners  90  to secure brackets  70  and support blocks  80 . 
       FIG. 4  illustrates an exemplary handrail installation showing the relative positions of top rail  10 , post cover  20 , post cap  26 , post skirt  28 , bottom rail  50 , and interconnecting balusters  30 B. It should be noted that in this exemplary embodiment, any or all of the components may be fabricated as described above to provide a durable, weather-resistant, and aesthetically pleasing railing system. 
       FIGS. 5 and 6  illustrate a bracket  70  and support block  80 , respectively, that may be used to connect the principal components of a handrail system together. Holes  72 ,  74 , and  82  are adapted to accept fasteners  90  to facilitate the assembly of the rail system. Angled surface portions  76  and  84  on bracket  70  and support block  80 , respectively, allow component connections over a range of angles to accommodate different installation configurations, such as angled walkways, decks, or stairways. As a result, in an exemplary embodiment of the present invention, bracket  70  and support block  80  may be used for perpendicular as well as angled connections of a rail to a post or post cover  20 . Thus, the versatility of bracket  70  and support block  80  eliminates the need for different components for perpendicular and angled connections, which may lead to additional benefits including, but not limited to, reduced manufacturing cost and installation time. 
     In the example of  FIG. 5 , angled surface portion  76  is at about a 45-degree angle relative to surface portion  78 , through which holes  74  extend in a notably oblique manner relative to surface portion  78 . Similarly, in the example of  FIG. 6 , angled surface portion  84  is at about a 45-degee angle relative to surface portion  86 , through which holes  82  extend. Such as in this example, at least one hole  82  may extend through surface portion  84  to surface portion  86 . As will be shown in subsequent figures, the angled configurations of the bracket  70  and support block  80  may facilitate connections of a rail to a post or post cover  20  over a range of angles. Although these exemplary embodiments of bracket  70  and support block  80  may be used for a 45-degree connection of a rail to a post or post cover  20 , it should also be recognized that these exemplary components may be used to for other angled connections (e.g., less than or greater than 45 degrees) of a rail to a post or post cover  20 . In addition, it should be recognized that other exemplary embodiments of the bracket and support block may have angled configurations that are less than or greater than 45 degrees and may also allow connections over a range of angles. In fact, in some exemplary embodiments of the present invention, the bracket and support block may not have angled configurations and may still allow for connections over a range of angles. 
       FIG. 7  illustrates one exemplary embodiment of component assembly for perpendicular connections of rails to a post or post cover. In this example, support block  80  is used to support lower support rail  40 . Holes  82  are provided so that the support block  80  may be secured to a post, a post cover, or any other desired support structure by fasteners. Optionally, a support block may also include other holes for receiving fasteners to secure the support block to a support rail. Brackets  70  may be similarly used to secure support rails  40  to a post, post cover, or any other desired support structure. In particular, fasteners may be inserted through holes  74  to secure brackets  70  to a support structure. In addition, although not visible in this view, fasteners may also be inserted through holes  72  to secure each bracket  70  to a support rail  40 . 
     Support rails  40  provide a structural foundation upon which to attach top rail  10  and bottom rail  50 . A support rail  40  may include at least one hollow.  FIG. 3B  shows an example of a support rail  40  that includes two hollows, whereas the support rail  40  of the exemplary embodiment shown in  FIG. 7  also includes a third (e.g., intermediate or center) hollow. It should be recognized that a support rail  40  may include no hollows or any other desired number of hollows in other exemplary embodiments of the invention. The example of a support rail  40  in  FIG. 3B  may improve fastener retention. 
     Each rail has a cavity that is adapted to receive a support rail  40 . For example, such as shown in  FIG. 7 , each rail may have a cavity that is adapted to mate with a support rail  40 . Upper rail  10  and lower rail  50  may simply be placed over respective support rails  40 , which promotes a relatively easy installation. Fasteners  90  may be used to directly or indirectly secure top rail  10  and, optionally, bottom rail  50  to the respective support rails  40 . As can be seen in  FIG. 7 , this configuration enables support rails  40 , brackets  70 , support block  80 , and fasteners  90  to be substantially or totally obscured from view during normal use of the railing assembly. Moreover, in addition to the pleasing aesthetic appearance of the resulting railing assembly, this exemplary embodiment of the present invention provides a weather-resistant covering for the support components. 
     In the example of  FIG. 7 , each support rail  40  is oriented such that it has a generally H-shaped configuration. This orientation enables the brackets  70  and support block  80  to provide both perpendicular and angled connections of a rail over a range of angles, wherein the rail may be generally horizontal, if desired. As mentioned above, fasteners  90  may be used to secure top rail  10  and bottom rail  50  to respective support rails  40 . Fasteners  90  may also be used to directly or indirectly connect balusters  30 B and squash block  60  to respective support rails  40 . Additionally, alignment grooves  42 , as illustrated in  FIG. 3B , may be provided on support rail  40  to provide an easy and quick method of locating fasteners  90  along the centerline, if desired, of the support rail  40 . For the same reason, bottom rail  50  may optionally include an alignment groove  52 . Similarly, top rail  10  may include an alignment groove, if desired. Optionally, holes may also be provided in predetermined locations (e.g., in the alignment grooves  42  and  52 ) for the reception of fasteners  90 . Such fastener holes may be pre-drilled or otherwise pre-formed before assembly, or such fastener holes may be drilled or otherwise formed during assembly. 
       FIG. 8A  illustrates a cross-sectional view of another exemplary embodiment of a baluster  30 B, which may be a hollow tubular-like structure.  FIG. 8B  illustrates an example of an exemplary embodiment of a baluster plug  32 , which optionally may comprise a grooved periphery to allow the application and retention of an adhesive or bonding agent.  FIG. 8C  illustrates a cross-sectional view of a baluster assembly  34  with may comprise a baluster  30 B with a baluster plug  32  installed on at least one end portion of the baluster  30 B. Alternatively, a single baluster plug  32  may extend the full length of the baluster  30 B. In either case, the baluster plug or plugs  32  may be drilled before or after assembly within the baluster  30 B to accommodate appropriate assembly fasteners  90 .  FIG. 8D  depicts a baluster plug  36  comprising a pre-drilled or otherwise pre-formed fastener hole  37 . For example, baluster plug  36  may be molded (e.g., extruded) such that it has fastener hole  37 .  FIG. 8E  illustrates an example of a baluster assembly  38  that includes baluster plug(s)  36 .  FIG. 8F  shows another example of a baluster plug  36 A comprising a plurality of protrusions on its periphery and a fastener hole  37 A, and  FIG. 8G  shows an example of a baluster assembly that includes baluster plug(s)  36 A. It should be noted that the baluster  30 B and baluster plugs  32 ,  36 , and  36 A may be comprised of a plastic, plastic composite material, or any other similar or suitable material such as described herein and may be fabricated by molding, extrusion, or any other suitable process or method known to those skilled in the art. Furthermore, it should be recognized that exemplary embodiments of a squash block may also be comprised of components similar to the above-described baluster assemblies  34  and  38  as well as the exemplary baluster assembly of  FIG. 8G . 
       FIGS. 9 through 11  illustrate various views of an exemplary assembly configuration showing the installation of a lower support rail  40 . In this example, support rail  40  is substantially perpendicular to post cover  20 . As shown in the partial view of  FIG. 11 , support rail  40  rests on support block  80 . Although  FIG. 11  shows a straight rail configuration, it is evident that support block  80  may enable angled connections up to about 45 to 50 degrees in this example. In addition, as shown in  FIGS. 9 and 10 , a bracket  70  is used to secure support rail  40  to the post cover  20 . In this exemplary configuration, fasteners  90  are aligned with the centerline of support rail  40 . 
       FIGS. 12 and 13  show in more detail the component relationship between a bracket and support rail in a straight rail configuration. As shown in  FIG. 12 , surface portion  78  of bracket  70  may be substantially aligned with edge  46  of support rail  40 . Fasteners  90  may be inserted through holes  72  in bracket  70  to secure bracket  70  to support rail  40 . Fasteners  90  may also be inserted through holes  74  in surface portion  78  in order to secure bracket  70  and support rail  40  to post cover  20 .  FIG. 13  shows lower rail  50  installed over lower support rail  40 .  FIG. 13  also shows the installation of balusters  30 B and upper support rail  40 . In an exemplary embodiment, balusters  30 B may be pre-assembled between upper support rail  40  and lower rail  50  using fasteners  90  so that these components may be installed as a single unit to facilitate installation in the field. Prior to being fastened, balusters  30 B may be spaced along the rail as desired. 
     In the example of  FIG. 12 , it should be note that the support rail  40  embodies an alignment groove  42 , which provides a ready reference that may be used to easily locate fasteners  90  for securing bracket  70  to support rail  40 . As previously noted, support rail  40  may be drilled or otherwise provided with holes to accommodate assembly fasteners  90 . The alignment groove  42  may be embodied onto the surface of the support rail  40  by means of a groove during the manufacturing process, such as extrusion, or it may be subsequently applied by means of a marking method, such as through the use of marking inks, etching, or other methods known to those knowledgeable in the art. 
       FIGS. 14 and 15  illustrate an example of how bracket  70  may be attached to support rail  40  for an angled rail installation. In this example, support rail  40  may be cut or formed in any other suitable manner such that it has an angled edge  48 . The angle of edge  48  may be selected to provide the desired angular connection between the rail and post cover  20 . Surface or face portion  78  of bracket  70  may be substantially aligned with angled edge  48  of support rail  40 . Fasteners  90  may be inserted through holes  72  in bracket  70  in order to secure bracket  70  to support rail  40 . As shown in this example, at least one of the holes  72  may aligned with optional alignment groove  42  in order to properly position bracket  70  on support rail  40 . In other words, the center fastener is aligned with the alignment groove  42  in this example. As depicted in  FIG. 15 , angled edge  48  may be situated against (e.g., adjacent) post cover  20 . Fasteners  90  may be inserted through holes  74  in surface portion  78  in order to directly or indirectly secure bracket  70  and support rail  40  to post cover  20  (e.g., via an underlying post), thereby providing the desired angular connection. Lower rail  50  may have an edge that has an angle similar to that of edge  48 , and it may be situated over lower support rail  40  as shown in  FIG. 15 .  FIG. 15  also shows balusters  30 B and upper support rail  40 . 
       FIG. 16  shows a different arrangement of the above-described components for applications requiring rails on changing elevations, for example, as in a stair rail. This configuration allows a rail to be connected to a support structure over a range of angles. As a result, this configuration may be used when a rail is supported at different levels, such as in a stair system or in any other system in which a rail is not level. Relative to the example shown in  FIG. 7 , support rails  40 , brackets  70 , and support blocks  80  are rotated about 90 degrees as shown in the example of  FIG. 16 . As a result, in this configuration, each support rail  40  is positioned such that it is substantially I-shaped. At least one of the support rails  40  is supported by a support block  80 . Brackets  70  may be used in conjunction with fasteners  90  to effectively (e.g., directly or indirectly) secure respective support rails  40  to a support structure, such as a post cover  20  or any other available support surface (e.g., a building wall). Fasteners  90  may also be used to secure support rail  40  to baluster  30 B. Optionally, each support rail may have at least one alignment groove  44  to assist in aligning the support rail with baluster  30 B. If desired, holes may also be provided in predetermined locations (e.g., in the alignment grooves  44  and  52 ) for the reception of fasteners  90 . Such fastener holes may be pre-drilled or otherwise pre-formed before assembly, or such fastener holes may be drilled or otherwise formed during assembly. 
       FIGS. 17 through 20  illustrate the component assembly relationships in an exemplary stair rail application requiring changes in rail elevation. As shown in  FIG. 17 , fasteners  90  may be inserted through holes  82  to secure support block  80  to post cover  20 .  FIG. 18  shows the subsequent positioning of a support rail  40  relative to support block  80 .  FIG. 19  depicts an exemplary attachment of a bracket  70  to a support rail  40 . In an exemplary embodiment, bracket  70  may be pre-mounted to support rail  40  using fasteners  90 . Fasteners  90  may also be inserted through holes  74  of bracket  70  to secure support rail  40  and bracket  70  to post cover  20  (e.g., via an underlying post).  FIG. 20  illustrates an exemplary installation of a lower support rail  40  in a stair rail application. 
       FIGS. 21A through 21H  illustrate an exemplary set of sequential steps for an exemplary installation of this invention as a handrail or guard.  FIG. 21A  depicts an installed post  100 , which may be built, for example, on the perimeter of a walkway (e.g., a residential deck).  FIG. 21B  illustrates the installation of a post skirt  28  around post  100 . Post cover  20  is next installed over post  100  and into the post skirt  28  as shown in  FIG. 21C . Support block  80  may be installed on the post cover  20  using an optional template  88  to assist with positioning, as shown in  FIG. 21D . This optional template  88  may be placed on post skirt  28  or a deck to consistently position the support block  80  during installation and may be made of plastic, cardboard, metal, or any other suitable material. For convenience, it may be included as a “punch out” feature in the packaging for the railing components, or it may be supplied separately. If integrated into the packaging, it may be punched or cut out prior to or after the railing components have been removed from the packaging. In order to assist with positioning support block  80 , an opening may be punched or cut out of template  88  for receiving support block  80 , and the sides of template  88  may optionally be folded such that template  88  wraps around opposing sides of post cover  20 . In this exemplary embodiment, support block  80  is aligned with the centerline of post cover  20  for both angled and straight sections. Furthermore, support block  80  is oriented such that the angled edge is in the desired direction.  FIG. 21E  shows the placement of lower support rail  40  on support block  80  (not shown). Optionally, lower support rail  40  may be pre-assembled with at least one squash block  60 , which may be secured with fasteners  90 . In addition, bracket  70  may be secured to lower support rail  40  prior to placing lower support rail  40  on support block  80 . After placing lower support rail  40  on support block  80 , fasteners  90  may be used to secure bracket  70  and lower support rail  40  to post cover  20 . Alternatively, lower support rail  40  may first be placed on support block  80 , and then bracket  70  may be secured to lower support rail  40  and post cover  20  with fasteners  90 .  FIG. 21F  next illustrates the installation of a lower rail  50 , balusters  30 B, and upper support rail  40 . In an exemplary method, balusters  30 B may first be secured between upper support rail  40  and lower rail  50  to form a sub-assembly. As can be seen in  FIG. 3C , lower rail  50  may optionally include a protruding edge  54 , which may provide a convenient alignment surface against which to mount balusters  30 B. The sub-assembly may then be installed such that the lower rail  50  is positioned over lower support rail  40 . In other exemplary installation methods, balusters  30 B, upper support rail  40 , and lower rail  50  may be installed individually or in various sub-combinations. It should be noted that a bracket  70  is installed on the upper support rail  40  and is subsequently connected to the post cover  20  to secure the rail assembly into position.  FIG. 21G  illustrates the installation of the upper or handrail  10 , which may simply be placed over upper support rail  40 . Fasteners  90  may subsequently be used to secure upper or handrail  10  to upper support rail  40 . For example, fasteners  90  may be inserted (e.g., screwed) upward through upper support rail  40  in order to engage and secure upper or handrail  10 . Lastly,  FIG. 21H  shows the installation of a finishing post cover cap  26  onto the post cover  20  to provide a weather-resistant barrier to the elements and provide a pleasing finished look to the rail system. 
       FIGS. 22A through 22D  illustrate an exemplary set of sequential steps of an exemplary installation of this invention as a stair rail guard.  FIG. 22A  shows an installation of two post covers  20  and support blocks  80 . As described above with regard to the handrail application, support blocks  80  may be positioned using an optional template or templates.  FIG. 22B  next shows an installation of a lower support rail  40 , which is supported by a support block  80  on each post cover  20 . Such as shown in  FIG. 16  or  FIG. 19 , brackets  70  may be used to directly or indirectly secure lower support rail  40  to each post cover  20 . In an exemplary method, brackets  70  may be secured to lower support rail  40  prior to or during installation.  FIG. 22C  next shows the installation of balusters  30 B, lower rail  50 , and upper support rail  40 . Balusters  30 B may be cut, mitered, or otherwise formed to have angled edges suitable for this type of application. Similar to the above-described installation of a handrail, balusters  30 B may first be secured between upper support rail  40  and lower rail  50  to form a sub-assembly. The sub-assembly may then be installed such that the lower rail  50  is positioned over lower support rail  40 . In other exemplary installation methods, balusters  30 B, upper support rail  40 , and lower rail  50  may be installed individually or in various sub-combinations. Again, it should be noted that a bracket  70  is installed on the upper support rail  40  and is subsequently directly or indirectly connected to the post cover  20  to secure the rail assembly into position. Next,  FIG. 22D  shows the installation of the upper or handrail  10  and post cover caps  26  to complete an exemplary stair rail assembly. Finally,  FIG. 22E  shows an exemplary embodiment of a template  88 A, which may be used to facilitate the positioning of a support block  80  on a support structure such as, but not limited to, a post, which may include a post cover  20 . In this example, template  88 A may be aligned with an edge of post cover  20  to facilitate positioning. In other exemplary embodiments, a template may wrap around at least one corner of a post cover, for example, to facilitate positioning. 
       FIGS. 23 and 24  illustrate a new and improved bracketing system  110 . A portion  111  may be pivotally connected to another portion (e.g., a metal plate  120 ) by means of any type of pivotal connection such as a rivet  150  or a male/female pivotal connection, for example. In an exemplary embodiment, the first portion  111  may move freely and smoothly around portion  120 . Portion  120  may contain one or more holes  130  for the insertion of fasteners (e.g., to secure the bracketing system  110  to a rail). Furthermore, portion  111  may contain holes  112 , which are preferably angled relative to the portion  120  as previously described, and an additional optional hole  113  for the insertion of fasteners. For instance, fasteners may be inserted through holes  112  to secure bracketing system  110  to a desired object including, but not limited to, a post. A fastener may be inserted through hole  113  to secure bracketing system  110  to a desired object including, but not limited to, a rail. Such as is illustrated in  FIG. 24 , hole  140  in portion  120  may accommodate use of a fastener in hole  113  while portion  111  is at any desired vertical or horizontal angle (e.g., up to and including a 45 degree angle in one exemplary embodiment). As a result, portion  111  may be rotated at an angle about portion  120  and thus allow for use of the bracketing system in applications requiring the use of an angled bracket. In fact, an exemplary embodiment of bracketing system  110  may be used similarly to the aforementioned embodiments of a bracket, while providing improved strength characteristics when installed due to the improved distribution of forces. 
       FIGS. 25 and 26  show perspective views of another embodiment of a bracketing system  151 . The system may employ a portion  155  that may rotate about another portion  156 . Holes  152 , which may be angled, may accommodate fasteners such as shown, and additional fasteners  153  and  154  may be used as well, such as described above. Fastener  153  may be inserted while portion  155  is at an angle relative to portion  156 . Portion  155  may be pivotally connected to portion  156  by means of pivotal connection  157  (e.g., a male/female pivotal connection) that may allow for rotation of bracket  155  within a desired radius. Again, an exemplary embodiment of bracketing system  151  may be used similarly to the aforementioned embodiments of a bracket, while providing improved strength characteristics when installed due to the improved distribution of forces provided by the pivotal system. 
       FIG. 27  shows another embodiment of a bracketing system  158  in which fasteners  159  may be inserted at an angle and fasteners  160  may be additionally employed. The bracketing system  158  may be comprised of two portions  161  and  162  so that portion  161  may rotate within a desired radius for applications which may require an angled bracket connection (e.g., a horizontal or vertical angle). Any suitable pivotal connection may be provided between portions  161  and  162 . In this example, portions  161  and  162  may also facilitate improved distribution of forces when installed, thereby improving the strength characteristics of a resulting railing system, for example. 
       FIGS. 28A through 28D  show various views of a portion  170  of another exemplary embodiment of a bracketing system of the present invention. In this example, portion  170  may be comprised of a mounting surface  171  and a base  172 . Mounting surface  171  may be in association with base  172  such that portion  170  is generally L-shaped such as shown in  FIG. 28A . For example, mounting surface  171  may be substantially vertical, and a bottom surface  173  of base  172  may be substantially perpendicular to mounting surface  171 . Base  172  may extend from mounting surface  171  such that a distal edge  174  of base  172  is generally curved, preferably rounded. As will be later described, curved distal edge  174  may facilitate angled installations of railing as well as a pivotal relationship with an associated portion of the bracketing system. Base  172  may include a female portion  175  that may facilitate an adjustable connection (e.g., a pivotal connection) with an associated portion of the bracketing system. For example, female portion  175  may be adapted to adjustably receive a rivet or a male portion of an associated portion of the bracketing system. In order to secure portion  170  to a desired object (e.g., a post), at least one hole may extend through mounting surface  171  for receiving a fastener. In this example, two holes  176  extend through mounting surface  171 . Such as shown in  FIG. 28C , mounting holes  176  preferably extend at an oblique angle in order to facilitate the insertion of fasteners. 
       FIGS. 29A through 29E  show an example of another portion  180  of a bracketing system that may be used in association with portion  170 . Portion  180  may be adjustably, preferably pivotally, connected to portion  170 . Portion  180  may be comprised of a body  181  having a top surface  182  and a bottom surface  183 . When assembled, bottom surface  183  may be in substantially the same plane as the bottom surface  173  of portion  170 . Body  181  may further include a side edge  184 , which may be generally curved (e.g., rounded) and extend downward relative to top surface  182 . As a result, when assembled, top surface  182  may extend over base  172  of portion  170 , and side edge  184  may be adjacent to distal edge  174  of portion  170  such that side edge  184  is adapted to be moved (e.g., rotated) around distal edge  174  of portion  170 . In this exemplary embodiment, a male portion  185  may extend downward relative to top surface  182 , whereby male portion  185  is adapted to be adjustably, preferably pivotally, received in female portion  175  of portion  170 . In other exemplary embodiments, it should be recognized that a rivet or any other suitable adjustable (e.g., pivotal) connection may be employed. One example of another suitable adjustable connection includes, but is not limited to, a reversed male/female connection. At least one anchor hole may extend through body  181 . In particular, three anchor holes  186  extend through body  181  in this example for receiving fasteners that may secure the resulting bracketing system to a desired object, such as a rail. At least one anchor hole  186  in portion  180  may help to distribute forces experienced by a resulting bracketing system when installed. Even further distribution of the forces that may be experienced by a resulting bracketing system when installed may be achieved by providing a triangular arrangement of anchor holes  186 , such as shown in  FIGS. 29A ,  29 C, and  29 E. As shown, portion  180  may be generally diamond-shaped, which may facilitate a desired arrangement of at least one anchor hole  186  for distributing forces that may be experienced by an installed bracketing system. Other suitable shapes of portion  180  may be employed including, but not limited to, rounded, curved, square, rectangular, polygonal, or any other suitable shape for the desired installation. 
       FIGS. 30A and 30B  show an exemplary installation of a bracketing system that may include portions similar to the above-described portion  170  and portion  180 . The example of  FIGS. 30A and 30B  show how an exemplary bracketing system may facilitate perpendicular or angled connections to a desired object (e.g., a post). The angled connections may be at horizontal or vertical angles, as desired. In this exemplary embodiment, each bracketing system  190  is secured to a rail  200  (e.g., a support rail). As shown, each bracketing system  190  is comprised of a portion  192  and a portion  194 . In this exemplary embodiment, as a result of the adjustable relationship between portion  192  and portion  194 , portion  192  may be generally square with the object (e.g., a post) to which it is desired to connect rail  200  regardless of the angle of the connection, whereas portion  194  may be generally aligned with rail  200  regardless of the angle of the connection. Such a configuration may improve the distribution of forces that may be experienced by an installed bracketing system, thereby improving the strength characteristics of a resulting railing system, for example. 
       FIGS. 31A through 31D  show another example of a bracketing system, which may be similar to the bracketing system shown in  FIGS. 30A and 30B . In this example, bracketing system  210  is comprised of a portion  220  that is adjustably (e.g., pivotally) connected to a portion  230 . As shown in  FIGS. 32A through 32E , portion  220  may be similar to portion  180  of  FIGS. 29A through 29E , with the exception being that portion  220  has rounded corner portions  222 . Rounded corner portions  222  may provide improved distribution of forces, particularly in the event that a rounded corner portion  222  comes into contact with a railing component when installed. In such situations, rounded corner portion  222  may limit the stress on the railing portion, thereby limiting damage to the railing portion. Nevertheless, it should be recognized that it may be preferred in some installations that rounded corner portions  222  promote clearance from an associated railing component when installed such that rounded corner portions  222  do not come into contact with the railing component. Somewhat similarly, portion  230  may have generally rounded sides  232  as shown in  FIGS. 33A through 33C . Rounded sides  232  may also provide improved distribution of forces in the event that a rounded side  232  comes into contact with a railing component when installed. However, it should again be recognized that it may be preferred in some installations that rounded sides  232  promote clearance from an associated railing component when installed such that rounded sides  232  do not come into contact with the railing component. Optionally, as shown in  FIGS. 33B and 33C , portion  230  may have a substantially square bottom edge  234 , as compared to the rounded bottom edge of potion  170  shown in  FIGS. 28A through 28C . Otherwise, the exemplary embodiment of portion  230  may be substantially similar to the exemplary embodiment of portion  170 . 
     The aforementioned bracketing systems may be comprised of any suitable materials. Examples of materials include, but are not limited to, metals and plastics and other similar or suitable materials. One example of a metal is die cast aluminum or zinc alloy, and one example of a plastic is a nylon alloy, such as DUPONT ZYTEL nylon alloy, which may provide desirable flexible or elastic properties for some installations for handling stresses. Other similar or suitable metals and plastics may also be used. 
     The immediately preceding examples of bracketing systems may be capable of pivotal movement. Nevertheless, other types of adjustment are also possible. For instance, in one exemplary embodiment, the portions of a bracketing system may be adapted to be separated and then secured together (e.g., snapped together) in any desired angular position. In other exemplary embodiments, the portions of an exemplary bracketing system may be self-retaining. 
     Referring again to the other railing components, a component of an exemplary embodiment of the present invention may be made from any suitable materials, unless expressly claimed otherwise. Although many materials may be used to fabricate the components disclosed herein, one exemplary embodiment may employ composite material that may be resistant to weathering and easily integrated into structures, such as railing. In one exemplary embodiment, a capstock layer (e.g., a PVC capstock layer) may be placed over a composite substrate to form an upper or handrail  10 , support rail  40 , bottom rail  50 , squash blocks  60 , balusters  30 A or  30 B, post covers  20 , and ancillary components, such as post skirts  28  and caps  26 , thereby providing a system of components that may be easily assembled into a rail. The capstock layer may be comprised of PVC, which may be placed over the composite substrate by any suitable fabrication method, such as co-extrusion, compression molding, injection molding, or other similar or suitable methods. The capstock layer and base material combination may allow lower cost, less attractive, and structurally rigid materials to be used as a base framework upon which an attractive and protective PVC capstock layer may be applied. Nevertheless, it should be recognized that other suitable materials may be used such as, but not limited to, wood, metal, composites, plastics, and other similar or suitable materials. 
     In one exemplary embodiment of the present invention, a substrate may be comprised of a composite that has a high cellulosic content. In particular, the composite may be comprised of cellulosic material in the amount of at least about 50% by weight and a plastic material in an amount of up to about 50% by weight. For instance, in one exemplary embodiment, the composite may be comprised of cellulosic material in the amount of about 55% by weight and a plastic material in an amount of about 45% by weight. In yet another exemplary embodiment, the composite may be comprised of cellulosic material in the amount of about 60% by weight and a plastic material in an amount of about 40% by weight. 
     The high cellulosic content enables the cost-effective production of a substrate that has desirable structural characteristics. For example, the high cellulosic content promotes the desired durability, rigidity, flexibility, and other structural characteristics for a variety of types of components. For instance, the high cellulosic content may enable the cost-effective production of railing components that exceed load testing requirements. 
     The cellulosic material may be virgin or recycled. Examples of cellulosic material include sawdust, newspapers, alfalfa, wheat pulp, wood chips, wood fibers, wood particles, ground wood, wood flour, flax, wood flakes, wood veneers, wood laminates, paper, cardboard, straw, cotton, rice hulls, coconut shells, peanut shells, bagasse, plant fibers, bamboo fiber, palm fiber, kenaf, and other similar, suitable, or conventional materials. Any of the wood examples may be hard or soft wood or variations thereof. Furthermore, any desired mesh size of the cellulosic material can be used. With regard to wood flour, an exemplary range of mesh size is about 10 to about 100 mesh, more preferably about 20 mesh to about 80 mesh depending on the desired characteristics of the composite. 
     The cellulosic material may be dried to a desired moisture content prior to or during the formation of the base layer. For example, the cellulosic filler(s) may be dried to about 0.5% to about 3% moisture content by weight, more preferably to about 1% to about 2% moisture content by weight. However, it should be recognized that the cellulosic material may have a moisture content less than about 0.5% by weight or greater than about 3% by weight and still be within the scope of the present invention. 
     The plastic material may be comprised of virgin or recycled materials that may improve the characteristics of the reinforced composite and/or enhance the manufacture or moldability thereof. In an exemplary embodiment of the present invention, the plastic material is a PVC material, which enables the production of a component having structural characteristics suitable for railing or other structurally demanding applications. The PVC material may, for example, be made by mixing PVC resin with, optionally, at least one stabilizer, at least one lubricant, at least one process aid, and other optional ingredients (e.g., acrylic modifier, inorganic filler, and other suitable additives). Optionally, another plastic resin may also be included in the composite such as, but not limited to, acrylonitrile butadiene styrene (i.e., ABS) resin. An example of a mixer is a high intensity mixer such as those made by Littleford Day Inc. or Henschel Mixers America Inc. As an example, the mechanically induced friction may heat the ingredients to a temperature between about 200° F. and about 230° F. After mixing, the ingredients may be cooled to ambient temperature. Alternatively, the ingredients of the PVC material may be mixed together during the formation of the base layer. 
     With reference to a plastic material that comprises PVC resin, the plastic material may include stabilizer(s) in an amount of about 1 to about 10 parts, more preferably about 2 to about 4 parts, per 100 parts of the PVC resin. The lubricant(s) may be present in an amount of about 2 to about 12 parts, more preferably about 4 to about 11 parts, per 100 parts of the PVC resin. Also, process aid(s) may be included in an amount of about 0.5 to about 8 parts, more preferably about 0.7 to about 3 parts, per 100 parts of the PVC resin. Optionally, acrylic modifier(s) (e.g., impact modifiers) may be present in an amount of about 1 to about 10 parts, more preferably about 4 to about 8 parts, per 100 parts of the PVC resin. As a further option, inorganic filler(s) may be added in an amount of up to about 10 parts, more preferably about 3 to about 9 parts, per 100 parts of the PVC resin. In addition, another plastic resin (e.g., ABS resin or any other similar or suitable resin) may be included in an amount up to about 50% by weight of the composite, more preferably about 5-10% by weight of the composite. 
     Stabilizer(s) may be employed to limit or prevent the breakdown of the plastic material during molding. Examples of stabilizers include tin stabilizers, lead and metal soaps such as barium, cadmium, and zinc, and other similar or suitable materials. 
     Internal or external lubricant(s) may aid in the molding process. Lubricants may be added to the plastic material to assist the reinforced composite through an extruder, compounder, or other molding machine, and to help facilitate mold release. Examples of lubricants include zinc stearate, calcium stearate, esters, amide wax, paraffin wax, ethylene bis-stearamide, and other similar or suitable materials. 
     Process aid(s) may aid in the fusion of the compound. Examples of process aids include acrylic process aids and other similar or suitable materials for improving the fusion of the compound. R&amp;H K-120N and R&amp;H K-175 are examples of acrylic process aids that are available from Rohm &amp; Haas. 
     Acrylic modifier(s) may improve the physical characteristics of the compound. One example of an impact modifier is Arkema P530. Another example of an acrylic modifier is R&amp;H K-400, which is available from Rohm &amp; Haas. Although R&amp;H K-400 is a high molecular weight acrylic modifier that is specifically designed for PVC foam applications, the inventors have discovered that it may also improve the physical characteristics of the base layer of the present invention, which has a high cellulosic content and may not include any foaming or blowing agents. 
     Inorganic filler(s) may be used to increase the bulk density of the reinforced composite. The use of inorganic filler may also improve the ability to process the reinforced composite, thereby allowing for higher rates of manufacture (e.g., extrusion). Inorganic filler may also allow the reinforced composite to be molded into articles having reduced moisture sensitivity and reduced flame and smoke spread. Examples of inorganic fillers include talc, calcium carbonate, kaolin clay, magnesium oxide, titanium dioxide, silica, mica, barium sulfate, wollastanite, acrylics, and other similar or suitable materials. 
     Other optional ingredients that may be included in the PVC material include, but are not limited to, polymers, plastics, thermoplastics, rubber, cross-linking agents, accelerators, inhibitors, enhancers, blowing agents/foaming agents, compatibilizers, thermosetting materials, pigments, weathering additives, and other similar or suitable materials. 
     Blowing agent(s) may be used to reduce the cost (e.g., by reducing the amount of polymer used in the composite) and weight of the composite material. A blowing agent may be an endothermic or exothermic blowing agent. An example of a chemical endothermic blowing agent is Hydrocerol BIH (i.e., sodium bicarbonate/citric acid), which is available from Clariant Corp., whereas an example of a chemical exothermic foaming agent is azodicarbonamide, which is available from Uniroyal Chemical Co. 
     The use of thermosetting materials may, for example, reduce moisture absorption and increase the strength of products manufactured from the reinforced composite material. Examples of thermosetting materials include polyurethanes (e.g., isocyanates), phenolic resins, unsaturated polyesters, epoxy resins, and other similar or suitable materials. Combinations of the aforementioned materials are also examples of thermosetting materials. 
     Pigments may be used to give the composite a desired color (e.g., white, cedar, gray, and redwood). Examples of pigments include titanium dioxide, iron oxide, and other similar or suitable colorant additives. 
     Titanium dioxide is also an example of a weathering additive. Other similar or suitable weathering additives include, but are not limited to, other ultraviolet absorbers. Examples of other ultraviolet absorbers include organic chemical agents such as benzophenone and benzotriazole types. 
     Due to the high cellulosic content of some exemplary embodiments, a base layer may not provide the desired aesthetic characteristics. As a result, the present invention may provide a capstock layer on the base layer. The capstock layer is preferably comprised of PVC. The use of a capstock layer may enable lower cost, less attractive, yet structurally desirable materials that have a high cellulosic content to be used as the base framework. For instance, the capstock layer may be applied on the base layer to provide an attractive and protective finish for the component. For example, the capstock layer may be provided in any desired color (e.g., to match the appearance of a deck or building exterior), and it may have a smooth outer surface or a pattern or texture formed on its outer surface. 
       FIGS. 1 and 2  show examples in which a capstock layer covers the entire exterior surface of the profile. If desired, a capstock layer may also be applied on the interior surface of the profile. It should also be recognized that a capstock layer may only cover a limited portion of the interior or exterior surface of the base layer in certain embodiments of the present invention. Furthermore, some examples may not include a capstock layer. 
     A component of the present invention may be manufactured using any suitable manufacturing techniques. For example, a base layer and a capstock layer of a railing component may be co-extruded. Alternatively, the capstock layer may be applied on the base layer (or vice versa) in a sequential extrusion process. Other molding techniques including, but not limited to, injection molding and compression molding may be used to manufacture a component of the present invention. In addition, it should be recognized that the optional layers of a railing component may be formed separately and then joined then in a subsequent process, such as with the use of adhesives or other suitable bonding materials. 
     Examples 
     One example of a composite that may be used to make a component comprises ingredients in the following amounts: 
     
       
         
           
               
               
               
             
               
                   
               
               
                   
                 PARTS PER 100 PARTS 
                   
               
               
                 INGREDIENT 
                 OF RESIN 
                 WEIGHT PERCENT 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 wood flour 
                 150 
                 55.1 
               
               
                 PVC resin 
                 100 
                 36.8 
               
               
                 lubricant 
                 7.5 
                 2.8 
               
               
                 acrylic modifier 
                 6 
                 2.2 
               
               
                 calcium carbonate 
                 5 
                 1.8 
               
               
                 tin stabilizer 
                 2.5 
                 0.9 
               
               
                 process aid 
                 1 
                 0.4 
               
               
                   
               
            
           
         
       
     
     Another example of a composite that may be used to make a component comprises ingredients in the following amounts: 
     
       
         
           
               
               
               
             
               
                   
               
               
                   
                 PARTS PER 100 PARTS 
                   
               
               
                 INGREDIENT 
                 OF RESIN 
                 WEIGHT PERCENT 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 wood flour 
                 183 
                 60 
               
               
                 PVC resin 
                 100 
                 32.8 
               
               
                 lubricant 
                 7.5 
                 2.5 
               
               
                 acrylic modifier 
                 6 
                 2 
               
               
                 calcium carbonate 
                 5 
                 1.6 
               
               
                 tin stabilizer 
                 2.5 
                 0.8 
               
               
                 process aid 
                 1 
                 0.3 
               
               
                   
               
            
           
         
       
     
     A third example of a composite that may be used to make a component comprises ingredients in the following amounts: 
     
       
         
           
               
               
               
             
               
                   
               
               
                   
                 PARTS PER 100 PARTS 
                   
               
               
                 INGREDIENT 
                 OF RESIN 
                 WEIGHT PERCENT 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 wood flour 
                 146.6 
                 50.0 
               
               
                 PVC resin 
                 100 
                 34.1 
               
               
                 ABS resin 
                 18.4 
                 6.3 
               
               
                 thermal stabilizer 
                 3.75 
                 1.3 
               
               
                 lubricant 
                 10 
                 3.4 
               
               
                 impact modifier 
                 6.0 
                 2.1 
               
               
                 process aid 
                 1 
                 0.3 
               
               
                 calcium carbonate 
                 7.5 
                 2.6 
               
               
                   
               
            
           
         
       
     
     A fourth example of a composite that may be used to make a component comprises ingredients in the following amounts: 
     
       
         
           
               
               
               
             
               
                   
               
               
                   
                 PARTS PER 100 PARTS 
                   
               
               
                 INGREDIENT 
                 OF RESIN 
                 WEIGHT PERCENT 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 wood flour 
                 179.3 
                 55.0 
               
               
                 PVC resin 
                 100 
                 30.7 
               
               
                 ABS resin 
                 18.4 
                 5.7 
               
               
                 thermal stabilizer 
                 3.75 
                 1.2 
               
               
                 lubricant 
                 10 
                 3.1 
               
               
                 impact modifier 
                 6.0 
                 1.8 
               
               
                 process aid 
                 1 
                 0.3 
               
               
                 calcium carbonate 
                 7.5 
                 2.3 
               
               
                   
               
            
           
         
       
     
     A fifth example of a composite that may be used to make a component comprises ingredients in the following amounts: 
     
       
         
           
               
               
               
             
               
                   
               
               
                   
                 PARTS PER 100 PARTS 
                   
               
               
                 INGREDIENT 
                 OF RESIN 
                 WEIGHT PERCENT 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 wood flour 
                 220 
                 60.0 
               
               
                 PVC resin 
                 100 
                 27.3 
               
               
                 ABS resin 
                 18.4 
                 5.0 
               
               
                 thermal stabilizer 
                 3.75 
                 1.0 
               
               
                 lubricant 
                 10 
                 2.7 
               
               
                 impact modifier 
                 6.0 
                 1.6 
               
               
                 process aid 
                 1 
                 0.3 
               
               
                 calcium carbonate 
                 7.5 
                 2.1 
               
               
                   
               
            
           
         
       
     
     While specific examples of materials may be given for making the components of the present invention, it should again be recognized that the present invention is not limited to the use of any particular materials unless expressly claimed otherwise. 
     Any embodiment of the present invention may include any of the optional or preferred features of the other embodiments of the present invention. The exemplary embodiments herein disclosed are not intended to be exhaustive or to unnecessarily limit the scope of the invention. The exemplary embodiments were chosen and described in order to explain the principles of the present invention so that others skilled in the art may practice the invention. Having shown and described exemplary embodiments of the present invention, those skilled in the art will realize that many variations and modifications may be made to affect the described invention. Many of those variations and modifications will provide the same result and fall within the spirit of the claimed invention. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.