Vertical cable rail barrier

Abstract

A barrier panel is formed of a first rail member and a second rail member with at least one vertical support member mounted to and extending between the first rail member and second rail member. The first rail member includes first openings spaced apart along its length. The second rail member includes second openings spaced apart along its length. Vertical cables are mounted to and extend between the first rail member and second rail member. A first end of each vertical cable is secured within one of the first openings and a second end of each vertical cable is secured within an opposite one of the second openings. End members configured to adjust tension in the vertical cables are concealed by a pair of leg members of the second rail member.

Claims

1. A vertical cable rail panel, comprising: a top rail comprising a cap member coupled to a top web member, the top web member defining a plurality of top through holes spaced apart along the top web member and the top rail having a first end and a second end disposed opposite the first end; a bottom rail defining a first end and a second end disposed opposite the first end, the bottom rail comprising a bottom web portion and a pair of bottom leg portions, the bottom web portion and the pair of bottom leg portions forming a channel, the bottom web portion defining a plurality of bottom through holes spaced apart along the bottom web portion and aligned with the plurality of top through holes; an internal member disposed within the channel and defining a bearing surface spaced apart from the bottom web portion and further defining a bottom opening having at least one flat side, the internal member being secured to inner surfaces of the channel; a rigid support member vertically extending between the top rail and the bottom rail and disposed between the first end of the top rail and the second end of the top rail; a vertical cable comprising a cable member, a top hollow tubular member, and a bottom hollow tubular member, the vertical cable disposed adjacent the rigid support member and having a top end and a bottom end disposed opposite the top end, the top end of the vertical cable extending through one of the plurality of top through holes, and the bottom end of the vertical cable extending through the bottom opening and extending through one of the plurality of bottom through holes disposed in vertical alignment with the one top through hole; wherein the top hollow tubular member is swaged to the cable member and at least a portion of the top hollow tubular member being larger in size than the one top through hole such that the vertical cable is maintained through the one top through hole; wherein the bottom hollow tubular member is swaged to the cable member; a nut coupled to the bottom hollow tubular member, the nut being larger in size than the bottom opening, wherein adjusting the nut adjusts a tension in the vertical cable, a bearing surface of the nut contacting the bearing surface of the internal member; and wherein each of the first and second ends of the top rail and the bottom rail are configured to be received by respective brackets.

2. The vertical cable rail panel of claim 1 wherein the bottom hollow tubular member is a portion of a threaded member, the threaded member being sized to fit through the bottom opening, the bottom hollow tubular member having a flat surface, the nut in threaded engagement with the threaded member.

3. The vertical cable rail panel of claim 1 wherein the bottom hollow tubular member is a portion of a threaded swage fitting, the threaded swage fitting including a threaded member, the threaded member being sized to fit through the bottom opening, the threaded swage fitting having a flat surface, the nut in threaded engagement with the threaded member.

4. The vertical cable rail panel of claim 1 wherein the bottom hollow tubular member is a portion of a bottom cable fitting further comprising a shank member, the shank member having a square outer shape and each of the plurality of bottom through holes is square shaped.

5. The vertical cable rail panel of claim 1 wherein the bottom hollow tubular member is a portion of a bottom cable fitting further comprising a shank member, the shank member being integral with a threaded member.

6. The vertical cable rail panel of claim 1 wherein at least one end of the rigid support member includes a threaded opening, and further including a threaded connector configured to engage with the threaded opening and mount the at least one end of the rigid support member to either the top rail or the bottom rail.

7. The vertical cable rail panel of claim 1 wherein the top hollow tubular member extends through the one top through hole and the bottom hollow tubular member extends through the one bottom through hole.

8. The vertical cable rail panel of claim 1 wherein the internal member comprises a U-shaped channel member.

9. The vertical cable rail panel of claim 1 wherein the top rail comprises a U-shaped channel member.

10. The vertical cable rail panel of claim 1 wherein the internal member is welded to the inner surfaces of the channel.

11. The vertical cable rail panel of claim 1 wherein the internal member includes an internal web member and a pair of opposed internal leg members extending from the internal web member.

12. The vertical cable rail panel of claim 1 wherein the top hollow tubular member is a portion of a top cable fitting further comprising a ball larger in size than the one top through hole.

13. The vertical cable rail panel of claim 1 wherein the internal member comprises an angled tab.

14. The vertical cable rail panel of claim 1 wherein the cap member comprises a base member and an ornamental member secured to the base member.

15. The vertical cable rail panel of claim 14 wherein the base member is a U-shaped channel member.

16. A method of forming a barrier, comprising: positioning a first post spaced apart from a second post and a third post spaced apart from the second post; supporting a first vertical cable panel with the first and second posts; supporting a second vertical cable panel with the second and third posts; wherein each of the first and second vertical cable panels, comprises: a top rail comprising a top web member defining a plurality of top through holes spaced apart along the top web member and the top rail having a first end and a second end disposed opposite the first end; a bottom rail defining a first end and a second end disposed opposite the first end, the bottom rail comprising a bottom web portion and a pair of bottom leg portions, the bottom web portion and the pair of bottom leg portions forming a channel, the bottom web portion defining a plurality of bottom through holes spaced apart along the bottom web portion and aligned with the plurality of top through holes; an internal member disposed within the channel and defining a bearing surface spaced apart from the bottom web portion and further defining a bottom opening having at least one flat side, the internal member being secured to inner surfaces of the channel; a rigid support member vertically extending between the top rail and the bottom rail and disposed between the first end of the top rail and the second end of the top rail; a vertical cable comprising a cable member, a top hollow tubular member, and a bottom hollow tubular member, the vertical cable disposed adjacent the rigid support member and having a top end and a bottom end disposed opposite the top end, the top end of the vertical cable extending through one of the plurality of top through holes, and the bottom end of the vertical cable extending through the bottom opening and extending through one of the plurality of bottom through holes disposed in vertical alignment with the one top through hole; wherein the top hollow tubular member is swaged to the cable member and at least a portion of the top hollow tubular member being larger in size than the one top through hole such that the vertical cable is maintained through the one top through hole; wherein the bottom hollow tubular member is swaged to the cable member; a nut coupled to the bottom hollow tubular member, the nut being larger in size than the bottom opening, wherein adjusting the nut adjusts a tension in the vertical cable, a bearing surface of the nut contacting the bearing surface of the internal member; and wherein each of the first and second ends of the top rail and the bottom rail are configured to be received by respective brackets.

17. The method of claim 16 wherein the top rail further comprises a cap member coupled to the top web member.

18. The method of claim 16 wherein the bottom hollow tubular member is a portion of a threaded member, the threaded member being sized to fit through the bottom opening, the bottom hollow tubular member having a flat surface, the nut in threaded engagement with the threaded member.

19. The method of claim 16 wherein the bottom hollow tubular member is a portion of a threaded swage fitting, the threaded swage fitting including a threaded member, the threaded member being sized to fit through the bottom opening, the threaded swage fitting having a flat surface, the nut in threaded engagement with the threaded member.

20. The method of claim 16 wherein the bottom hollow tubular member is a portion of a bottom cable fitting further comprising a shank member, the shank member having a square outer shape and each of the plurality of bottom through holes is square shaped.

21. The method of claim 16 wherein the bottom hollow tubular member is a portion of a bottom cable fitting further comprising a shank member, the shank member being integral with a threaded member.

22. A vertical cable rail panel, comprising: a top rail comprising a top web member defining a plurality of top through holes spaced apart along the top web member and the top rail having a first end and a second end disposed opposite the first end; a bottom rail defining a first end and a second end disposed opposite the first end, the bottom rail comprising a bottom web portion and a pair of bottom leg portions, the bottom web portion and the pair of bottom leg portions forming a channel, the bottom web portion defining a plurality of bottom through holes spaced apart along the bottom web portion and aligned with the plurality of top through holes; an internal member disposed within the channel and defining a bearing surface spaced apart from the bottom web portion and further defining a bottom opening having at least one flat side, the internal member being secured to inner surfaces of the channel; a rigid support member vertically extending between the top rail and the bottom rail and disposed between the first end of the top rail and the second end of the top rail; a vertical cable comprising a cable member, a top hollow tubular member, and a bottom hollow tubular member, the vertical cable disposed adjacent the rigid support member and having a top end and a bottom end disposed opposite the top end, the top end of the vertical cable extending through one of the plurality of top through holes, and the bottom end of the vertical cable extending through the bottom opening and extending through one of the plurality of bottom through holes disposed in vertical alignment with the one top through hole; wherein the top hollow tubular member is swaged to the cable member and at least a portion of the top hollow tubular member being larger in size than the one top through hole such that the vertical cable is maintained through the one top through hole; wherein the bottom hollow tubular member is swaged to the cable member; a nut coupled to the bottom hollow tubular member, the nut being larger in size than the bottom opening, wherein adjusting the nut adjusts a tension in the vertical cable, a bearing surface of the nut contacting the bearing surface of the internal member; wherein each of the first and second ends of the top rail and the bottom rail are configured to be received by respective brackets; and wherein the top rail, the bottom rail, the rigid support member, and the vertical cable are assembled into a panel before delivery to a job site.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A more complete understanding of the method and apparatus of the present invention may be acquired by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein:

(2) FIG. 1 is a front view of an embodiment of a cable rail panel;

(3) FIG. 2 is a perspective view of a bottom rail;

(4) FIG. 3 is a cross-sectional view of the bottom rail;

(5) FIG. 4 is a perspective view of a top rail;

(6) FIG. 5A illustrates a first end of a cable;

(7) FIG. 5B illustrates a second end of a cable;

(8) FIGS. 6A-6D illustrate cable installation on the bottom and top rails;

(9) FIG. 7 is a broken away side view showing a means for attaching vertical support members;

(10) FIG. 8 illustrates an end view of a cap member;

(11) FIG. 9 illustrates installation of the cap member; and

(12) FIG. 10 illustrates an alternative cap member; and

(13) FIGS. 11A-11E illustrate an implementation of the cable rail panel useful in a stair or sloped installation.

DETAILED DESCRIPTION

(14) Reference is now made to FIG. 1 which illustrates a front view of an embodiment of a cable rail panel 10 (configured to be installed between two post members 18). The panel 10 includes a bottom rail 12 and a top rail 14 that are spaced apart from each other by a pair of vertical support members 16 (extending between the bottom and top rails) which are spaced apart from each other along the lengths of the bottom and top rails. The bottom rail 12, top rail 14 and vertical support members 16 are made of a metal material (such as steel or aluminum). First ends of the vertical support members are fixedly attached (for example, by bolts, welding or brackets) to the bottom rail 12. Second ends of the vertical support members are fixedly attached (also, for example, by bolts, welding or brackets) to the top rail 14. The panel 10 further includes a plurality of vertical cables 19 spaced apart from each other along the lengths of the bottom and top rails and extending between the bottom and top rails. The means for cable attachment will be discussed in more detail herein. Each end of the bottom and top rails is configured for attachment to the post member 18, for example, through the use of a bracket mechanism as known in the art.

(15) In an embodiment, the vertical support members 16 are hollow tubular members having a desired cross-section including, for example, square, rectangular, circular, hexagonal, octagonal, or the like. In an alternative embodiment, the vertical support members 16 are solid bar members having a desired cross-section including, for example, square, rectangular, circular, hexagonal, octagonal, or the like. In either case, a threaded opening may be provided at each end of the member 16 to accept a mounting bolt for attachment of the vertical member to the top and bottom rails.

(16) Reference is now made to FIG. 2 which illustrates a perspective view of the bottom rail 12 and further to FIG. 3 which illustrates a cross-sectional view of the bottom rail 12. The bottom rail is formed of a first U-shaped channel member 20 and a second U-shaped channel member 22. The channel members 20 and 22 are made of a metal material, such as steel or aluminum, and are fixedly attached to each other (for example, by welding) with the first channel member 20 fitting within the second channel member 22 and the open ends of the two channel members oriented facing each other. The welded attachment may, for example, comprise welding edges or surfaces of the channel member 20 to inner surfaces of the channel member 22. Spot or resistance welding techniques may be used in a manner well known to those skilled in the art. In a preferred implementation, evidence of the welding would not be visible on an outer surface of the channel member 22.

(17) Each channel member 20 and 22 is formed of a web member and an opposed pair of leg members extending generally perpendicularly from the web member. The first channel member 20 is formed of the web member 21 and the opposed pair of leg members 23. The second channel member 22 is formed of the web member 25 and the opposed pair of leg members 27. The space between the leg members 23 defines the open end of the channel member 20. The space between the leg members 27 defines the open end of the channel member 22. The web member 21 for the first channel member 20 includes a plurality of first openings 26 and the web member 25 for the second channel member 22 includes a plurality of second openings 28. When the channel members 20 and 22 are fixedly attached to each other, the first and second openings 26 and 28 align with each other. Furthermore, with reference once again to FIG. 1, the aligned first and second openings are provided at locations along the lengths of the channel members 20 and 22 which corresponding to the desired locations of vertical cables 19 (and also the desired locations of the vertical support members 16 in a certain embodiment). Indeed, as will be discussed in more detail below, the first and second openings 26 and 28 are provided in connection with supporting the attachment of first ends of the plurality of vertical cables 19 to the bottom rail 12 (and perhaps attachment of first ends of the vertical support members 16).

(18) The openings 26 and 28 may have any desired shape, but in a preferred implementation the openings have square or rectangular cross-sectional shapes.

(19) The first channel member 20 functions to provide reinforcement or stiffness to the assembly with the second channel member 22 to form the bottom rail 12. The first channel member 20 further functions in connection with supporting bottom rail 12 for retention of first ends of the plurality of vertical cables 19.

(20) Reference is now made to FIG. 4 which illustrates a perspective view of the top rail 14 (the cross-section of top rail being similar to that of the bottom rail shown in FIG. 3). The top rail is formed of a first U-shaped channel member 30 and a second U-shaped channel member 32. The channel members 30 and 32 are made of a metal material, such as steel or aluminum, and are fixedly attached to each other (for example, by welding) with the first channel member 30 fitting within the second channel member 32 and the open ends of the two channel members oriented facing each other. The welded attachment may, for example, comprise welding edges or surfaces of the channel member 30 to inner surfaces of the channel member 32. Spot or resistance welding techniques may be used in a manner well known to those skilled in the art. In a preferred implementation, evidence of the welding would not be visible on an outer surface of the channel member 32.

(21) Each channel member 30 and 32 is formed of a web member and an opposed pair of leg members extending generally perpendicularly from the web member. The web member for the first channel member 30 includes a plurality of first openings 36 and the web member for the second channel member 32 includes a plurality of second openings 38. When the channel members 30 and 32 are fixedly attached to each other, the first and second openings 36 and 38 align with each other. Furthermore, with reference once again to FIG. 1, the aligned first and second openings are provided at locations along the lengths of the channel members 30 and 32 which corresponding to the desired locations of vertical cables 19 (and also the desired locations of the vertical support members 16 in a certain embodiment). Indeed, as will be discussed in more detail below, the first and second openings 36 and 38 are provided in connection with supporting the attachment of second ends of the plurality of vertical cables 19 to the top rail 14 (and perhaps attachment of second ends of the vertical support members 16).

(22) The openings 36 and 38 may have any desired shape, but in a preferred implementation the openings have square or rectangular cross-sectional shapes.

(23) The first channel member 30 functions to provide reinforcement or stiffness to the assembly with the second channel member 32 to form the top rail 14. The first channel member 30 further functions in connection with supporting top rail 14 retention of second ends of the plurality of vertical cables 19.

(24) Reference is now made to FIG. 5A which illustrates a first end of a vertical cable 19. The cable 19 is formed of a cable member 40 that is made of metal, for example, stainless steel. The cable member 40 may be of a wound, woven or solid (rod) type as desired and is to some degree flexible along its length. At the first end, a ball swage fitting 42 is attached. The ball swage fitting 42 includes a ball member 44 and a shank member 46. The shank member 46 is a hollow tubular member sized to receive the end of the cable member 40 which is fixedly attached within the shank member 46. The shank member 46 may, for example, have an outer shape in the form of a square or rectangle generally conforming to the size and shape of the openings 26 and 28 provided in the bottom rail 12 (or alternatively the openings 36 and 38 of the top rail 14). The ball member 44 is sized larger than the openings 26 and 28 (or 36 and 38).

(25) Reference is now made to FIG. 5B which illustrates a second end of a vertical cable 19. The cable 19 is formed of the cable member 40 as described above. At the second end, a threaded swage fitting 52 is attached. The threaded swage fitting 52 includes a threaded member 54 and a shank member 56. The shank member 56 is a hollow tubular member sized to receive the end of the cable member 40 which is fixedly attached within the shank member 56. The shank member 56 may, for example, have an outer shape in the form of a square or rectangle generally conforming to the size and shape of the openings 36 and 38 provided in the top rail 14 (or alternatively the openings 26 and 28 provided in the bottom rail 12). The threaded member 54 likewise is sized to fit through the openings 36 and 38 (or 26 and 28). A nut 58 is provided to be installed on the threaded member 54 and it is sized larger than the openings 36 and 38 (or 26 and 28).

(26) Reference is now made to FIG. 6A which illustrates an end view of top rail 14 with an installed ball swage fitting 42. The ball member 44 is sized larger than the opening 36 in the first channel member 30 and the shank member 46 is sized for press fit through the openings 36 and 38 in the channel members 30 and 32. FIG. 6C shows a perspective view of the installed ball swage fitting 42 extending through the openings 38 in the top rail 14. It will be understood that alternatively the fitting 42 could be used in connection the bottom rail 12.

(27) Reference is now made to FIG. 6B which illustrates an end view of bottom rail 12 with an installed threaded swage fitting 52. The nut 58 is sized larger than the opening 26 in the first channel member 20 and the shank member 56 and threaded member 54 are sized to pass freely through the openings 26 and 28 in the channel members 20 and 22. Tightening of the nut 58 on the threaded member 54 permits adjustments to be made as to the tensioning of the cable 19. The nut 58 is tightened against the channel member 20 such that a bearing surface 59 of the nut 58 contacts a corresponding bearing surface 29 of the channel member 20.

(28) Reference is now made to FIG. 7 which illustrates a means for attaching the vertical support members 16 to the bottom rail 12 and top rail 14. FIG. 7 shows a rail member 60 which may comprise either a bottom rail 12 or a top rail 14. The rail member 60 has a configuration like that shown in FIGS. 2 and 4 and thus includes a plurality of aligned openings 62 and 64 in channel members 20 and 22 used for supporting installation of the swage fittings. Instead of fixedly attaching the vertical support member 16 by means of welding, the vertical support member 16 may instead be secured to the rail member 60 at any of the opening 62/64 locations using mounting hardware 66. In an embodiment, the mounting hardware 66 may, for example, comprise a bolt, screw or other threaded connector as known in the art. The shaft of such hardware passes through the openings 62/64 and engages a threaded opening provided in the end of the vertical support member. The head of such hardware engages with the inner channel member. An advantage of this assembly is that the vertical support members 16 can be installed at any opening along the length of the top and bottom rail members. Thus, rail members can be cut to desired length at the job site and the one or more vertical support members 16 provided at desired locations along that length. One end of each of the plurality of cables 19 is then installed in the remaining openings 62/64 to complete assembly of the panel as shown in FIG. 1 wherein the ends of each cable are supported with opposite openings in the rails 12 and 14.

(29) Reference is now made to FIG. 8 which illustrates an end view of a cap member 90 that is configured for installation over the top rail 14. FIG. 9 illustrates the cap member 90 in an installed position. The cap member 90 is formed of one or more U-shaped channel members 92 which may comprise a base member 92a and an ornamental member 92b. The base member 92a is designed for press or interference fit over the channel member 32. The ornamental member 92b is secured to the base member 92a through any suitable means (including, for example, welding, adhesion, hardware like screws, etc.) and includes ornamental features 94 as desired (only one non-limiting example of such ornamentation being shown).

(30) In an alternative embodiment, the open end of the top rail 14 may be closed or covered using other means. For example, FIG. 10 illustrates the use of a wooden member 96 which can be secured to the top rail 14 using any suitable means (including, for example, a clip mechanism and hardware attachment).

(31) Although the ball end of the swage fitting may be configured for mounting to openings in the bottom rail, it will be understood that this is a matter of installation choice and instead the ball end of the swage fitting could be mounted to openings in the top rail. Although the threaded end of the swage fitting may be configured for mounting to openings in the top rail, it will be understood that this is a matter of installation choice and instead the threaded end of the swage fitting could be mounted to openings in the bottom rail.

(32) There may exist certain installations, such as with stairs or other sloped terrain, where a perpendicular panel configuration like that shown in FIG. 1 is not preferred. In such cases, it would be preferred to install a panel that is configured to have the top and bottom rails and cables of the panel run parallel to the slope as shown in FIG. 11A.

(33) The panel 10 is accordingly configured to support racking so as to follow undulating terrain, stairways or ramps. For example, the panel may be racked to an angle up to about 35. In this configuration, the connection between the vertical support members 16 and both the bottom rail 12 and top rail 14 permits other than perpendicular mounting. Additionally, the brackets used to attach the ends of the bottom rail 12 and top rail 14 to the posts 18 permits other than perpendicular mounting. More detail is provided below and in connection with FIGS. 11B-11E.

(34) To support this installation, the panel includes a hinge 140 for connecting the ends of the vertical support members 16 to each of the rails 12 and 14. See, FIG. 11B. The hinge 140 provides a pivot point 142 between a rail bracket 144 and a support bracket 146. In the illustrated configuration, the support bracket 146 includes a pair of opposed flanges 148 and the rail bracket 144 includes a tab member 150 that is inserted between and pivotally coupled to the flanges 148. The rail bracket 144 may be attached to the rail 12/14 using the openings 26/28 or 36/38 and mounting hardware. The support bracket 146 may be attached to an end of the support member 16 using mounting hardware, or alternatively may be integrally formed at the end of the support member 16.

(35) In order to support angled attachment of the ends of the cable, the top and bottom rails 12/14 are configured such that an angled tab 172 is cut out from the web member 174 of the first channel member 20/30 at each opening 26/36. See, FIGS. 11C-11E. A first end of the angled tab 172 remains attached to the web member 174 while a second end of the angled tab 172 is bent inwardly towards the web member 176 of the second channel member 22/32. In an embodiment, the second end of the angled tab 172 is engaged (for example, by welding) against the inner surface of the web for the second channel member 22/32 (as shown at reference 180). The opening 26/36 still aligns with the opening 28/38 on the second channel member 22/32 and receives the fitting 178 which is attached to the cable end (see, FIGS. 5A-5B for examples of the fittings). The angle with which the tab 172 is bent may, in a preferred embodiment, be equal to about 30-40. It will be understood that the angle of the tab 172 may be selected to account for the slope of the stairs or sloped terrain at which the panel is to be installed. The alignment of the openings 26/36 and 28/38 is made in accordance with a range of permitted slope installations. To support such a range, the opening 28/38 in the second channel member is oversized with respect to the fitting.

(36) Although preferred embodiments of the method and apparatus of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth and defined by the following claims.