Reinforced Post Assemblies for Railing or Fencing Systems

Abstract

Reinforced post assemblies for railing or fencing systems that include: base plates; posts; and inserts, which are positioned within the posts and are directly connectable to the base plates. The inserts are configured for slidable insertion into the posts in a generally vertical direction and reinforce the posts assemblies to increase the strength and/or the rigidity thereof.

Claims

1. A reinforced post assembly for a railing or fencing system, wherein the reinforced post assembly comprises: a base plate; an insert directly connectable to the base plate; and a post receiving the insert such that the insert extends into the post.

2. The reinforced post assembly of claim 1, wherein the base plate includes: first openings configured to receive first fasteners to connect the base plate to a foundation; second openings configured to receive second fasteners to connect the base plate to the insert; and third openings configured to facilitate drainage of the reinforced post assembly.

3. The reinforced post assembly of claim 2, wherein the insert includes: a first boss and a second boss, wherein the first boss and the second boss are configured to receive the second fasteners.

4. The reinforced post assembly of claim 3, wherein the insert further includes: a first leg and a second leg extending from the first boss in generally opposite directions; and a third leg and a fourth leg extending from the second boss in generally opposite directions.

5. The reinforced post assembly of claim 1, wherein the insert is symmetrical about a first axis.

6. The reinforced post assembly of claim 5, wherein the insert is symmetrical about a second axis extending in generally orthogonal relation to the first axis.

7. The reinforced post assembly of claim 1, wherein the post includes receptacles configured to slidably receive the insert.

8. The reinforced post assembly of claim 1, wherein the post is fixedly connected to the base plate.

9. The reinforced post assembly of claim 1, wherein the post defines a first length, and the insert defines a second length less than the first length.

10. The reinforced post assembly of claim 1, wherein the post defines a first length, and the insert defines a second length approximately equal to the first length.

11. A reinforced post assembly for a railing or fencing system, wherein the reinforced post comprises: an insert including a plurality of legs; a post receiving the insert such that the plurality of legs extend into the post; and the insert; and a base plate indirectly connecting the insert and the post.

12. The reinforced post assembly of claim 11, wherein the plurality of legs are non-linear in configuration.

13. The reinforced post assembly of claim 12, wherein the plurality of legs include: first segments; and second segments extending from the first segments so as to define obtuse angles therebetween.

14. The reinforced post assembly of claim 11, wherein the post includes bosses configured to receive the plurality of legs.

15. The reinforced post assembly of claim 14, wherein the plurality of legs include bulbous tips configured for insertion into the bosses to facilitate reception of the insert by the post and inhibit twisting of the insert during assembly of the reinforced post assembly.

16. A reinforced post assembly for a railing or fencing system, wherein the reinforced post assembly defines a longitudinal axis and comprises: a base plate; a post connected to the base plate; and a first insert and a second insert positioned within and mechanically engaging the post, wherein the first insert and the second insert are configured as discrete components of the reinforced post assembly.

17. The reinforced post assembly of claim 16, wherein the post includes: a first boss; a second boss; a third boss; and a fourth boss, wherein the first boss, the second boss, the third boss, and the fourth boss extend in generally parallel relation to the longitudinal axis.

18. The reinforced post assembly of claim 17, wherein the first insert is configured for insertion into the first boss, the second boss, and the third boss, and the second insert is configured for insertion into the fourth boss.

19. The reinforced post assembly of claim 16, wherein the first insert and the second insert define a channel therebetween configured to receive a cable.

20. The reinforced post assembly of claim 16, wherein the first insert includes a first configuration, and the second insert includes a second configuration different than the first configuration.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. According to common practice, the various features of the drawings may not be to-scale, and the dimensions of the various features may be arbitrarily expanded or reduced. Additionally, certain components, elements, and/or features may be omitted from certain drawings in the interest of clarity.

[0010] FIG. 1 is a top, perspective view illustrating a railing or fencing system according to one embodiment of the present disclosure.

[0011] FIG. 2 is a top, perspective view illustrating a post assembly for the railing or fencing system seen in FIG. 1, which includes: a base plate; a base plate cover; an insert; a post; and an end cap.

[0012] FIG. 3 is a top, perspective view illustrating the post assembly seen in FIG. 2 shown with parts separated.

[0013] FIG. 4 is an enlargement of the area of detail identified in FIG. 3.

[0014] FIG. 5 is a partial, top, perspective view illustrating assembly of the post assembly seen in FIG. 2.

[0015] FIG. 6 is a top, plan view illustrating the base plate.

[0016] FIG. 7 is a bottom, perspective view illustrating the base plate.

[0017] FIG. 8 is a top, plan view illustrating the post.

[0018] FIG. 9 is a top, plan view illustrating the insert.

[0019] FIG. 10 is a partial, top, plan view illustrating the post assembly seen in FIG. 2 upon assembly.

[0020] FIG. 11 is a top, perspective view illustrating an alternate embodiment of the railing or fencing system seen in FIG. 1.

[0021] FIG. 12 is a partial, top, perspective view illustrating a post assembly for the railing or fencing system seen in FIG. 11, which includes alternate embodiments of the insert and the post.

[0022] FIG. 13 is a partial, cross-sectional view taken along line 13-13 in FIG. 11.

[0023] FIG. 14 is a partial, top, perspective view illustrating the post assembly seen in FIGS. 12 and 13 with the post shown in phantom.

[0024] FIG. 15 is a top, plan view illustrating posts for use in end post configurations of the post assembly seen in FIGS. 12 and 13, which are shown oriented in opposite directions.

[0025] FIG. 16 is a top, plan view illustrating a post for use in a line post configuration of the post assembly seen in FIGS. 12 and 13.

[0026] FIG. 17 is a top, plan view illustrating a post for use in a corner post configuration of the post assembly seen in FIGS. 12 and 13.

[0027] FIG. 18 is a partial, top, plan view illustrating a corner post configuration of the post assembly seen in FIGS. 12 and 13, which includes a first insert and a second insert.

[0028] FIG. 19 is a top, plan view illustrating the first insert.

[0029] FIG. 20 is a top, plan view illustrating the second insert.

[0030] FIG. 21 is a partial, bottom, perspective view illustrating the post assembly seen in FIG. 18 during insertion of the first insert into the post.

[0031] FIG. 22 is a partial, bottom, perspective view illustrating assembly of the post assembly seen in FIG. 18.

[0032] FIG. 23 is a partial, top, perspective view illustrating the post assembly seen in FIG. 18 during insertion of the second insert into the post.

[0033] FIG. 24 is a partial, top, plan view illustrating the post assembly seen in FIG. 18 upon assembly.

DETAILED DESCRIPTION

[0034] With reference now to FIG. 1, a railing or fencing system 10 is disclosed that includes: post assemblies 100 (also referred to as reinforced post assemblies); upper rails 200i and lower rails 200ii, which extend between the post assemblies 100; mounting brackets 300, which support the upper rails 200i and the lower rails 200i; and infills 400, which are positioned and/or extend between the post assemblies 100.

[0035] In the illustrated embodiment, the infills 400 are configured as balusters 402, which extend between the upper rails 200i and the lower rails 200ii. In various embodiments of the disclosure, however, it is envisioned that the configuration of the railing or fencing system 10 may be varied in order to suit a variety of installations and/or achieve a variety of aesthetic appearances. For example, in one embodiment of the railing or fencing system 10, the infills 400 include pickets or paneling in place of the balusters 402, whereas in another embodiment of the railing or fencing system 10, the infills 400 include cables 404 (FIG. 11) in place of the balusters 402, as described in further detail below.

[0036] Referring now to FIGS. 2-10 as well, the post assemblies 100 will be discussed. The post assemblies 100 are universal in that they may be configured and utilized as end post assemblies 100E (FIG. 1), line post assemblies 100L, or corner post assemblies 100C. The post assemblies 100 define longitudinal axes L (FIG. 2) and include: base plates 102; base plate covers 104; inserts 106 (also referred to as internal reinforcement members or reinforcement members); posts 108; and end caps 110.

[0037] In various embodiments of the disclosure, it is envisioned that the post assemblies 100 may be provided either disassembled, partially assembled, or completely assembled (e.g., depending upon the particular installation of the railing or fencing system 10).

[0038] The base plates 102 are anchored to a foundation (e.g., a deck, a patio, a footing, the ground, etc.) during installation of the railing or fencing system 10 and support the inserts 106 and the posts 108. The base plates 102 are monolithic (e.g., unitary, integral) in construction and are formed from a single piece of material. More specifically, in the illustrated embodiment, the base plates 102 are formed from extruded aluminum, which allows the base plates 102 to be punched during manufacture, thereby reducing the manufacturing cost and facilitating CNC machining of the base plates 102. Alternate material(s) and methods of construction for the base plates 102 are also envisioned herein, however.

[0039] With particular reference to FIGS. 4, 6, and 7, the base plates 102 include: openings 112 (also referred to as first openings or outer openings), which receive fasteners 114 (also referred to as first fasteners) that (mechanically) connect the post assemblies 100 to the foundation via the base plates 102; openings 116 (also referred to as second openings or inner openings), which receive fasteners 118 (also referred to as second fasteners) that (mechanically) connect the base plates 102 to the inserts 106, as described in further detail below; and openings 120 (also referred to as third openings or weep holes), which facilitate drainage of the post assemblies 100 via the base plates 102 and thereby inhibit (if not entirely prevent) corrosion.

[0040] In the illustrated embodiment, the base plates 102 include four of the openings 112 (e.g., openings 112i-112iv), two of the openings 116 (e.g., openings 116i, 116ii), and two of the openings 120 (e.g., openings 120i, 120ii). Embodiments in which the particular numbers of the openings 112, the openings 116, and/or the openings 120 are increased or decreased are also envisioned herein, however (e.g., depending upon the intended use of the post assemblies 100, the particular configurations of the posts 108 and the inserts 106, the required drainage, etc.).

[0041] In various embodiments, it is envisioned that the openings 112 and/or the openings 116 may be either threaded or non-threaded (e.g., depending upon the intended use of the post assemblies 100, the particular configurations of the fasteners 114 and the fasteners 118, etc.).

[0042] In order to further facilitate drainage of the post assemblies 100, in certain embodiments, the base plates 102 include channels 122 that extend outwardly from the openings 120i, 120ii, as seen in FIG. 7. More specifically, the channels 122 are formed in undersides 124 (bottom surfaces) of the base plates 102 and extend to the outer edges (the perimeters) thereof to direct water away from the openings 120.

[0043] The base plate covers 104 (FIGS. 1-3) extend about and conceal the base plates 102, thereby improving the overall aesthetic appearance of the post assemblies 100. Additionally, the base plate covers 104 facilitate the shedding of water to inhibit (if not entirely prevent) the entry of water into the post assemblies 100 and, thus, corrosion.

[0044] With particular reference to FIGS. 3-5, 9, and 10 the inserts 106 will be discussed. The inserts 106 reinforce (e.g., increase the strength and/or the rigidity of) the post assemblies 100 and are positioned (located) internally within the posts 108. It is envisioned that the specific dimensions of the inserts 106 may be dictated (determined) by the spatial tolerances provided by the posts 108 and that the inserts 106 may include any dimensions suitable for the intended purpose of facilitating reception of the inserts 106 by the posts 108 in the manner described herein. As such, depending upon the particular configurations of the posts 108 (e.g., the internal dimensions thereof), it is envisioned that the inserts 106 may be available in a wide variety of dimensions.

[0045] The inserts 106 are monolithic (e.g., unitary, integral) in construction and are formed from a single piece of material. More specifically, in the illustrated embodiment, the inserts 106 are formed from extruded aluminum. Alternate material(s) and methods of construction for the inserts 106 are also envisioned herein, however.

[0046] The inserts 106 are symmetrical about multiple axes, which allows for connection of the inserts 106 to the base plates 102 in multiple orientations, as well as positioning of the inserts 106 within the posts 108 in multiple orientations, thereby simplifying assembly of the post assemblies 100. More specifically, as seen in FIG. 9, the inserts 106 are symmetrical about axes X (also referred to as first axes or first axes of symmetry) and about axes Y (also referred to as a second axes or a second axes of symmetry), which extends in generally orthogonal (perpendicular) relation to the axes X.

[0047] The inserts 106 define axial lengths LI (FIG. 5) extending between the opposite ends thereof and include: bosses 126 (FIG. 9); legs 128; and braces 130.

[0048] The bosses 126 are positioned (located) and generally aligned along the axes X and receive the fasteners 118 (FIG. 4) in order to connect the inserts 106 to the base plates 102. In various embodiments, it is envisioned that the bosses 126 may be either threaded or non-threaded (e.g., depending upon the intended use of the post assemblies 100, the particular configurations of the base plates 102, the inserts 106, and the fasteners 118, etc.).

[0049] The bosses 126 include generally C-shaped transverse (e.g., horizontal) cross-sectional configurations defining receptacles 132 and slots 134. Embodiments in which the bosses 126 include generally annular (e.g., circular) transverse (e.g., horizontal) cross-sectional configurations are also envisioned herein, however.

[0050] In the illustrated embodiment, the inserts 106 include a boss 126i (also referred to as a first boss) and a boss 126ii (also referred to as a second boss). Embodiments in which the particular number of bosses 126 included on the inserts 106 are increased or decreased are also envisioned herein, however (e.g., depending upon the particular configurations of the base plates 102 and the inserts 106).

[0051] The legs 128 include generally identical, non-linear configurations and extend outwardly from the bosses 126. More specifically, the inserts 106 include legs 128i and legs 128ii (also referred to as first legs and second legs, respectively), which extend outwardly from the bosses 126i, and legs 128iii, 128iv (also referred to as third legs and fourth legs, respectively), which extend outwardly from the bosses 126ii. More specifically, the legs 128i, 128ii and the legs 128iii, 128iv are oriented in generally opposite directions such that the legs 128i, 128ii and the legs 128iii, 128iv mirror one another with respect to the axes X and such that the legs 128i, 128iii and the legs 128ii, 128iv mirror one another with respect to the axes Y.

[0052] The legs 128 include segments 136 (also referred to as first segments), which define lengths LS1, and segments 138 (also referred to as second segments), which defines lengths LS2 that are greater than the lengths LS1.

[0053] The segments 136 extend outwardly from the bosses 126 in generally parallel relation to the axes Y, and the segments 138 extend from the segments 136 in non-parallel and non-orthogonal (non-perpendicular) relation thereto. More specifically, the inserts 106 are configured such that the segments 136 and the segments 138 define angles therebetween, which not only facilitates (mechanical) engagement (contact) with the posts 108, as described in further detail below, but allow the legs 128 to avoid the mounting brackets 300 and the fasteners 302 (FIG. 24) used to connect the mounting brackets 300 to the post assemblies 100.

[0054] In the illustrated embodiment, the inserts 106 are configured such that the angles are obtuse and lie substantially within the range of approximately 120 degrees to approximately 150 degrees (e.g., approximately 135 degrees). Embodiments in which the inserts 106 are configured such that the angles lie outside of the disclosed range are also envisioned herein, however (e.g., depending upon the particular respective lengths LS1, LS2 of the segments 136, 138).

[0055] The segments 138 include bulbous (e.g., rounded) tips 140 (e.g., at the ends thereof). The bulbous tips 140 define transverse (e.g., horizontal) cross-sectional dimensions D1 and facilitate not only assembly of the post assemblies 100 but (mechanical) engagement (contact) of the inserts 106 with the posts 108 as well as unintended (inadvertent) relative movement between the inserts 106 and the posts 108, as described in further detail below.

[0056] The braces 130 extend between the bosses 126, thereby (indirectly) connecting the legs 128 and increasing the strength (e.g., the rigidity) of the inserts 106. More specifically, the braces 130 extend between the bosses 126 in generally parallel relation to the axes X.

[0057] With particular reference to FIGS. 8 and 10, the posts 108 receive the inserts 106 and are configured for direct, fixed connection to the base plates 102, as described in further detail below. The posts 108 are monolithic (e.g., unitary, integral) in construction and are formed from a single piece of material. More specifically, in the illustrated embodiment, the posts 108 are formed from extruded aluminum and include generally square-shaped transverse (e.g., horizontal) cross-sectional configurations. Alternate material(s), methods of construction, and configurations (e.g., outer profiles or contours) for the posts 108 are also envisioned herein, however.

[0058] Depending upon the particular installation and the intended use of the post assemblies 100, it is envisioned that the posts 108 may include any suitable dimensions (e.g., widths W). For example, it is envisioned that the posts 108 may include widths W that lie substantially within the range of approximately 2 to approximately 5. Embodiments in which the posts 108 include widths W that lie outside of the disclosed range are also envisioned herein, however.

[0059] The configuration of the posts 108 described herein facilitates use of the post assemblies 100 as the aforementioned end post assemblies 100E (FIG. 1), line post assemblies 100L, and/or corner post assemblies 100C without requiring any adjustments or modifications to the base plates 102, the inserts 106, or the posts 108 themselves, thus supporting the universal functionality of the post assemblies 100.

[0060] The posts 108 include: opposite ends 142, 144 (also referred to as lower and upper ends, respectively); sidewalls 146i-146iv (also referred to as faces); interior chambers 148, which are configured to receive the inserts 106 in a vertical direction, as indicated above; and bosses 150, which extend from the ends 142 to the ends 144 (e.g., along the entirety of the lengths LP of the posts 108) in generally parallel relation to the longitudinal axes L (FIG. 2). As seen in FIG. 3, the posts 108 define axial lengths LP that extends between the opposite ends 142, 144 thereof.

[0061] In certain embodiments, it is envisioned that the lengths LP of the posts 108 may exceed the lengths LI of the inserts 106. For example, in one particular embodiment, the lengths LP of the posts 108 lie substantially within the range of approximately 36 to approximately 72 whereas the lengths LI of the inserts 106 lie substantially within the range of approximately 12 to approximately 24 (e.g., in order to reduce the cost of the post assemblies 100, inhibit (if not entirely prevent) interference with connection of the end caps 110 to the posts 108, etc.).

[0062] Embodiments in which the lengths LP of the posts 108 and the lengths LI of the inserts 106 are approximately equal (e.g., such that the inserts 106 substantially span the lengths LP of the posts 108 in their entirety) are also envisioned herein, however.

[0063] The bosses 150 are positioned (located) within the interior chambers 148 in corner portions 152i-152iv of the of the posts 108 and include generally C-shaped transverse (e.g., horizontal) cross-sectional configurations defining receptacles 154 and slots 156. In various embodiments, it is envisioned that the bosses 150 may be either threaded or non-threaded (e.g., depending upon the intended use of the post assemblies 100, the particular configuration of the end caps 110, etc.).

[0064] In the illustrated embodiment, the posts 108 include: bosses 150i (also referred to as first bosses), which are positioned (located) in corner portions 152i (also referred to as first corner portions) of the posts 108; bosses 150ii (also referred to as second bosses), which are positioned (located) in corner portions 152ii (also referred to as second corner portions) of the posts 108; bosses 150iii (also referred to as third bosses), which are positioned (located) in corner portions 152iii (also referred to as third corner portions) of the posts 108; and bosses 150iv (also referred to as fourth bosses), which are positioned (located) in corner portions 152iv (also referred to as fourth corner portions) of the posts 108.

[0065] The receptacles 154 and the slots 156 receive the legs 128 (FIG. 9) of the inserts 106, which is facilitated by the non-linear configuration thereof (e.g., the obtuse angles defined between the segments 136, 138). More specifically, the receptacles 154 receive the bulbous tips 140, and the slots 156 receive the segments 138 of the legs 128. Reception of the legs 128 by the receptacles 154 and the slots 156 facilitates vertical insertion of the inserts 106 into the posts 108, as described in further detail below. More specifically, as seen in FIG. 8, the receptacles 154 define transverse (e.g., horizontal) cross-sectional dimensions D2, which exceed the transverse (e.g., horizontal) cross-sectional dimensions D1 (FIG. 9) defined by the bulbous tips 140 on the legs 128 of the inserts 106, and the slots 156 define transverse (e.g., horizontal) cross-sectional dimensions D3, which are less than the transverse (e.g., horizontal) cross-sectional dimensions D1, such that, upon insertion of the legs 128 into the bosses 150 and connection of the posts 108 to the base plates 102, the legs 128 (e.g., the bulbous tips 140) are captive to the posts 108 (e.g., the bosses 150). Securing the legs 128 of the inserts 106 within the bosses 150 not only inhibits unintended (inadvertent) relative movement between the inserts 106 and the posts 108 (e.g., rotation and/or twisting of the inserts 106 during connection to the base plates 102 that may otherwise occur upon insertion of the fasteners 118 (FIG. 4)) but allows the posts 108 to act as jigs (assembly guides) for the inserts 106 in order to facilitate proper assembly of the post assemblies 100. Additionally, the inclusion of the bulbous tips 140 on the legs 128 allows for (mechanical) engagement (contact) between the inserts 106 and the posts 108 while avoiding any direct, fixed connection therebetween.

[0066] As seen in FIG. 10, upon engagement of the posts 108 and the inserts 106 (e.g., upon insertion of the legs 128 into the bosses 150), the inserts 106 and the posts 108 divide the interior chambers 148 (FIG. 8) into four internal quadrants 158 (e.g., internal quadrants 158i-158iv) with the legs 128 overlying the openings 120 such that the openings 120 span (extend across) the legs 128. Configuring the inserts 106 such that the legs 128 overlie the openings 120 allows the quadrants 158i, 158iv to drain via the opening 120i and the quadrants 158ii, 158iii to drain via the opening 120ii, thereby reducing the number of openings 120 in the base plates 102 and simplifying the manufacture thereof. Embodiments in which the base plates 102 include additional openings 120 (e.g., such that the number of openings 120 equals or exceeds the number of quadrants 158) are also envisioned herein, however.

[0067] The end caps 110 (FIGS. 1-3) are connected (secured) to the ends 144 of the posts 108 and conceal the interiors thereof, thereby improving the overall aesthetic appearance of the post assemblies 100 and inhibiting (if not entirely preventing) the entry of water into the post assemblies 100 and, thus, corrosion.

[0068] In various embodiments of the disclosure, it is envisioned that the end caps 110 may be configured to frictionally engage (contact) the ends 144 of the posts 108, that the end caps 110 may include projections (e.g., detents, pegs, fingers, etc.) that are configured for insertion into the bosses 150 (FIG. 8) on the posts 108 (e.g., in a press-fit arrangement), and/or that the end caps 110 may be (mechanically) connected to the posts 108 via fasteners (e.g., self-tapping screws) that are received by the bosses 150.

[0069] With continued reference to FIGS. 1-10, assembly of the post assemblies 100 will be discussed.

[0070] Initially, the base plates 102 are connected (secured) to the foundation via insertion of the fasteners 114 (FIG. 4) through the openings 112 in a generally vertical direction 1 (also referred to as a first direction). Thereafter, the inserts 106 are connected to the base plates 102 via insertion of the fasteners 118 in a generally vertical direction 2 (also referred to as a second direction), which is generally opposite to the direction 1. More specifically, the fasteners 118 are inserted through the undersides 124 of the base plates 102, into the openings 116, and into the bosses 126 (FIG. 9) on the inserts 106.

[0071] Following connection of the inserts 106 to the base plates 102, the posts 108 are oriented such that the bosses 150 (FIGS. 8, 10) are generally aligned with the legs 128 (FIGS. 9, 10) of the inserts 106. More specifically, the receptacles 154 are generally aligned with the bulbous tips 140 and the slots 156 are generally aligned with the segments 138 of the legs 128. The posts 108 are then slid vertically downward onto the legs 128 (e.g., in the direction 1 (FIG. 4)) such that the interior chambers 148 (FIGS. 8, 10) receive the inserts 106 during insertion into the posts 108. The posts 108 are then advanced vertically towards the base plates 102 over the inserts 106 until the ends 142 (FIG. 3) of the posts 108 contact the base plates 102.

[0072] After contacting the base plates 102, the posts 108 are directly and fixedly connected thereto, which establishes an indirect connection between the posts 108 and the inserts 106 (e.g., via the base plates 102). For example, in the illustrated embodiment, the posts 108 are secured to the base plate 102 via welds A (FIG. 10). Alternate methods of connecting the posts 108 to the base plates 102 are also envisioned herein, however.

[0073] With reference now to FIG. 11, a railing or fencing system 20 will be discussed, which is an alternate embodiment of the railing or fencing system 10 discussed above (FIG. 1).

[0074] The railing or fencing system 20 is substantially similar in both structure and function to the railing or fencing system 10 and, accordingly, in the interest of brevity, will only be discussed with respect to differences therefrom. As such, identical reference characters will be utilized to refer to elements, structures, features, etc., common to the railing or fencing system 10 and the railing or fencing system 20.

[0075] The railing or fencing system 20 includes: the upper rails 200i, which act as handrails or other such supports; the mounting brackets 300 supporting the upper rails 200i; post assemblies 500 (also referred to as reinforced post assemblies), which include end post assemblies 500E, line post assemblies 500L, and corner post assemblies 500C; and the infills 400. In contrast to the railing or fencing system 10 (FIG. 1), the infills 400 include the aforementioned cables 404, which replace the balusters 402 (FIG. 1).

[0076] Although generally illustrated and described as including the cables 404, it is envisioned that the infills 400 in the railing or fencing system 20 may include wires, cords, leads, chains, ropes, or the like, either in addition to or instead of the cables 404.

[0077] With reference now to FIGS. 12-24 as well, the post assemblies 500 will be discussed. The post assemblies 500 include: the base plates 102; the base plate covers 104; posts 508; and the end caps 110. Additionally, the end post assemblies 500E and the line post assemblies 500L include inserts 506 (FIGS. 11-13) (also referred to as internal reinforcement members or reinforcement members), and the corner post assemblies 500C include inserts 606 (FIGS. 18, 19, 21-24) (also referred to as first inserts, primary inserts, first internal reinforcement members, or first reinforcement members) and inserts 608 (FIGS. 18, 20, 23, 24) (also referred to as second inserts, secondary inserts, second internal reinforcement members, or second reinforcement members). As described in further detail below, the insert 606 and the insert 608 are configured as discrete (separate, disconnected, independent) components of the corner post assemblies 500C and are non-identical in configuration (e.g., the insert 606 includes a first configuration, and the insert 608 includes a second configuration different than the first configuration).

[0078] Referring to FIGS. 12-14 in particular, the inserts 506 will be discussed. The inserts 506 are generally identical to the inserts 106 (FIGS. 3-5, 9, 10) other than the inclusion of openings 560, which extend through the braces 130 in generally orthogonal (perpendicular) relation to the axes X (FIG. 9) and in generally parallel relation to the axis Y. The openings 560 are spaced axially along the lengths LI (FIGS. 5, 12) of the inserts 506 (and the longitudinal axes L (FIG. 2)) and are configured to receive the cables 404 such that the cables 404 extend through the inserts 506.

[0079] The posts 508 are generally identical to the posts 108 (FIGS. 3, 5, 8, 10) other than the inclusion of openings 562, which extend in generally orthogonal (perpendicular) relation to the longitudinal axes L. The openings 562 are spaced axially along the lengths LP (FIG. 3) of the posts 508 (and the longitudinal axes L) and are configured to receive the cables 404 such that the cables 404 extend into and/or through the posts 508.

[0080] In certain embodiments, it is envisioned that the openings 562 may be included on and may extend through each of the sidewalls 146i-146iv (FIGS. 8, 15-17) of the posts 508, whereas in other embodiments, it is envisioned that the openings 562 may be omitted from one or more of the sidewalls 146i-146iv. For example, as seen in FIG. 15, when utilized in the end post assemblies 500E (FIG. 11), the openings 562 are included in one of the sidewalls 146 (e.g., the sidewalls 146i) of the posts 508, as seen in FIG. 16, when utilized in the line post assemblies 500L (FIGS. 11, 13, 14), the openings 562 are included in opposite sidewalls 146 of the posts 508 (e.g., the sidewalls 146i, 146iii), and, as seen in FIG. 17, when utilized in the corner post assemblies 500C (FIG. 11), the openings 562 are included in adjacent sidewalls 146 thereof (e.g., the sidewalls 146i, 146iv).

[0081] In certain embodiments, the vertical positions (e.g., the heights) of the openings 560 in the inserts 506 correspond to those of the openings 562 in the posts 508 such that, upon assembly of the post assemblies 500, the openings 560 and the openings 562 are generally aligned along the longitudinal axes L. In other embodiments, however, it is envisioned that the vertical positions (e.g., the heights) of the openings 560 in the inserts 506 may be axially (e.g., vertically) offset from those of the openings 562 in the posts 508, as described in further detail below.

[0082] It is envisioned that the openings 560 in the inserts 506 and the openings 562 in the posts 508 may be either generally annular (e.g., circular) in configuration or non-annular (e.g., generally elliptical) in configuration, which not only increases tolerances and facilitates the use of a wide variety of cables 404 but allows for insertion of the cables 404 at an angle (e.g., in non-orthogonal (non-perpendicular) relation to the longitudinal axes L of the post assemblies 100).

[0083] For example, when installed on steps, stairs, or the like, it is envisioned that the cables 404 may extend at acute angles (e.g., approximately 45 degrees) in relation to the longitudinal axes L of the post assemblies 100, as seen in FIG. 14.

[0084] In such installations, in order to accommodate the angle of the cables 404, the vertical positions (e.g., the heights) of the openings 560 in the inserts 506 are axially (e.g., vertically) offset from those of the openings 562 in the posts 508. Additionally, in such installations, when utilized in the line post assemblies 500L (FIG. 16), the vertical positions (e.g., the heights) of the openings 562 in the opposite sidewalls 146 of the posts 508 (e.g., the sidewalls 146i, 146iii) are also axially (e.g., vertically) offset from each other.

[0085] In order to accommodate positional and height requirements during installations on steps, stairs, or the like, it is envisioned that the base plates 102, the inserts 506, and the posts 508 may be provided separately, rather than assembled, and that the inserts 506 and the posts 508 may be cut to the required height prior to installation.

[0086] Referring now to FIGS. 18-24 in particular, the inserts 606 and the inserts 608 will be discussed.

[0087] The inserts 606 are substantially similar in both structure and function to the inserts 106 and, accordingly, in the interest of brevity, will only be discussed with respect to differences therefrom. As such, identical reference characters will be utilized to refer to elements, structures, features, etc., common to the inserts 106 and the inserts 606.

[0088] In contrast to the inserts 106, the inserts 606 are asymmetrical. The inserts 606 define axial lengths LI1 (FIG. 21) extending between the opposite ends thereof and include: the bosses 126; the legs 128i, 128iii, 128iv; guide portions 664 (also referred to as first guide portions); and the braces 130.

[0089] The guide portions 664 replace the legs 128ii (FIG. 9) included on the inserts 106 and are non-linear (e.g., arcuate) in configuration. More specifically, the guide portions 664 include curved segments 666i, 666ii (also referred to as outer segments) and linear segments 668 (also referred to as inner segments), which connect the curved segments 666i, 666ii.

[0090] The inserts 608 further reinforce (e.g., increase the strength and/or the rigidity of) the corner post assemblies 500C (FIGS. 11, 18, 24) and are positioned (located) internally within the posts 508. Additionally, together with the inserts 606, the inserts 608 define channels 670 (FIGS. 18, 24) for the cables 404, as described in further detail below.

[0091] It is envisioned that the specific dimensions of the inserts 608 may be dictated (determined) by the spatial tolerances provided by the posts 508 and that the inserts 608 may include any dimensions suitable for the intended purpose of facilitating reception of the inserts 608 by the posts 508 in the manner described herein. As such, depending upon the particular configurations of the posts 508 (e.g., the internal dimensions thereof), it is envisioned that the inserts 608 may be available in a wide variety of dimensions.

[0092] The inserts 608 are monolithic (e.g., unitary, integral) in construction and are formed from a single piece of material. More specifically, in the illustrated embodiment, the inserts 608 are formed from extruded aluminum. Alternate material(s) and methods of construction for the inserts 608 are also envisioned herein, however.

[0093] The inserts 608 are symmetrical about a single axis R (FIG. 20) and define axial lengths LI2 (FIG. 23) extending between the opposite ends thereof. The inserts 608 include: bodies 672 and legs 674.

[0094] The bodies 672 are generally trapezoidal in configuration and include: outer walls 676 (FIG. 20); inner walls 678; and sidewalls 680, which collectively define hollow interior spaces 682 with the outer walls 676 and the inner walls 678, thereby reducing the weight and the cost of the corner post assemblies 500C (FIGS. 11, 18, 24).

[0095] The outer walls 676 correspond in configuration to the guide portions 664 (FIGS. 18, 19) on the inserts 606 and are non-linear (e.g., arcuate) in configuration. More specifically, the outer walls 676 include curved segments 684i, 684ii (also referred to as outer segments) and linear segments 686 (also referred to as inner segments), which connect the curved segments 684i, 684ii.

[0096] The inner walls 678 are generally linear in configuration and extend in generally parallel relation to the linear segments 686 of the outer walls 676.

[0097] As seen in FIGS. 18 and 24, upon assembly of the corner post assemblies 500C, the guide portions 664 of the inserts 606 and the outer walls 676 of the inserts 608 collectively define the channels 670, which receive and guide (route) the cables 404 (FIGS. 11, 24) between the openings 562 (FIGS. 21-23) in the sidewalls 146 of the posts 508 (e.g., the sidewalls 146i, 146iv). Additionally, the channels 670 define radii of curvature for the cables 404 as the cables 404 are passed (laced) through the posts 508 that is configured to inhibit (if not entirely prevent) excessive bending and damage to the cables 404 and/or the posts 508. The inserts 606, 608 thus offer dual functionality in that they not only reinforce the corner post assemblies 500C but guide (route) and protect the cables 404 during installation and use.

[0098] The sidewalls 680 (FIG. 20) extend between and connect the outer walls 676 (e.g., the curved segments 684i, 684ii) and the inner walls 678. More specifically, the inserts 608 are configured such that the sidewalls 680 define acute angles with the outer walls 676 (e.g., the curved segments 684i, 684ii) and obtuse angles with the inner walls 678. The configurations of the bodies 672 allow the sidewalls 680 to be oriented generally flush with the sidewalls 146i, 146iv of the posts 508 upon assembly of the corner post assemblies 500C, which not only inhibits (if not entirely prevents) relative movement between the inserts 608 and the posts 508 (e.g., rattling) but further reinforces the corner post assemblies 500C.

[0099] In the illustrated embodiment, the inserts 608 are configured such that the angles lie substantially within the range of approximately 60 degrees to approximately 80 degrees (e.g., approximately 70 degrees) and such that the angles lie substantially within the range of approximately 100 degrees to approximately 120 degrees (e.g., approximately 110 degrees). Embodiments in which the inserts 608 are configured such that the angles , lie outside of the disclosed ranges are also envisioned herein, however (e.g., depending upon the particular radius of curvature desired for the cables 404 upon insertion through the posts 508).

[0100] The legs 674 extend outwardly from the bodies 672 and include struts 688 (FIG. 20) and the aforementioned bulbous tips 140, which are positioned at ends 690 of the struts. During assembly the corner post assemblies 500C, the legs 674 are received by the bosses 150 (FIG. 18) on the posts 508 (e.g., the struts 688 and the bulbous tips 140 are respectively received by slots 156 (FIG. 8) and the receptacles 154). As discussed in connection with the inserts 106 (FIGS. 3-5, 9, and 10), reception of the legs 674 by the bosses 150 facilitates vertical insertion of the inserts 608 into the posts 508, as described in further detail below.

[0101] With continued reference to FIGS. 18-24, assembly of the corner post assemblies 500C will be discussed. Assembly of the corner post assemblies 500C is substantially similar to that of the post assemblies 100 (FIGS. 1-10) and, accordingly, in the interest of brevity, will only be discussed with respect to differences therefrom.

[0102] Initially, the base plates 102 are connected (secured) to the foundation in the manner discussed above. Thereafter, the inserts 606 are connected to the base plates 102 via insertion of the fasteners 118 (FIGS. 18, 24) into the bosses 126, and the posts 508 are oriented such that the bosses 150i, 150iii, 150iv (FIG. 18) are generally aligned with the legs 128i, 128iii, 128iv of the inserts 606 and such that the guide portions 664 span the bosses 150ii. More specifically, the receptacles 154 are generally aligned with the bulbous tips 140 and the slots 156 are generally aligned with the segments 138 of the legs 128i, 128iii, 128iv, as discussed above with respect to assembly of the post assemblies 100. The posts 508 are then slid vertically downward onto the legs 128i, 128iii, 128iv in the direction 1 (FIG. 4), the posts 508 are advanced vertically towards the base plates 102, and after contacting the base plates 102, the posts 508 are directly and fixedly connected thereto (e.g., via the welds A (FIG. 10)).

[0103] Following connection of the posts 508 to the base plates, the inserts 608 are oriented such that the bosses 150ii (FIG. 18) on the posts 508 are generally aligned with the legs 674. More specifically, the receptacles 154 are generally aligned with the bulbous tips 140 and the slots 156 are generally aligned with the struts 688.

[0104] The legs 674 are then inserted into the bosses 150ii as the inserts 608 are inserted and slid vertically downward into the interior chambers 148 (FIG. 18) of the posts 508. Upon insertion of the inserts 608 into the interior chambers 148, the insert 608 is (horizontally) separated from the insert 606, whereby the guide portions 664 and the outer walls 676 respectively included on the insert 606 and the insert 608 collectively define the channels 670.

[0105] As seen in FIGS. 18 and 24, upon positioning of the insert 606 and the insert 608 within the posts 508, the insert 606 and the insert 608 are devoid of any direct connection therebetween. Instead, the insert 606 and the insert 608 are indirectly connected via the posts 508.

[0106] Following insertion of the inserts 608, the upper rails 200i (FIGS. 11, 24) and the mounting brackets 300 are connected to the posts 508. As seen in FIG. 24, the insert 606 and the insert 608 are configured such that the mounting brackets 300 can be connected to the post 508 via the fasteners 302 without interfering with the channels 670 or the cables 404. More specifically, the insert 606 and the insert 608 are configured such that the respective lengths LI1, LI2 thereof are sufficient to accommodate each of the cables 404 but terminate short of the vertical positions of the mounting brackets 300 and the fasteners 302. Upon assembly of the corner post assemblies 500C, the fasteners 302 thus extend through the mounting brackets 300 and the posts 508 while avoiding the insert 606 and the insert 608.

[0107] Either prior or subsequent to connection of the upper rails 200i and the mounting brackets 300, the cables 404 are inserted through the openings 562 (FIGS. 21-23) in the posts 508. During insertion, the cables 404 pass through and are guided (routed) by the channels 670 (FIGS. 18, 24), which eliminates any need to manually bend the cables 404 or utilize the aforementioned cable guide typically relied upon during cable installations in known railing or fencing systems.

[0108] In an alternate method of installation, it is envisioned that the corner post assemblies 500C may be provided fully assembled and that the cables 404 may be inserted through the posts 508 prior to connection of the corner post assemblies 500C (e.g., the base plates 102) to the foundation.

[0109] In one aspect of the present disclosure, a reinforced post assembly for a railing or fencing system is disclosed that includes: a base plate; an insert that is directly connectable to the base plate; and a post that receives the insert such that the insert extends into the post.

[0110] In certain embodiments, the base plate may include: first openings, which are configured to receive first fasteners to connect the base plate to a foundation; second openings, which are configured to receive second fasteners to connect the base plate to the insert; and third openings, which are configured to facilitate drainage of the reinforced post assembly.

[0111] In certain embodiments, the insert may include a first boss and a second boss.

[0112] In certain embodiments, the first boss and the second boss may be configured to receive the second fasteners.

[0113] In certain embodiments, the insert may further include a first leg and a second leg, wherein the first leg and the second leg extend from the first boss in generally opposite directions.

[0114] In certain embodiments, the insert may further include a third leg and a fourth leg, wherein the third leg and the fourth leg extend from the second boss in generally opposite directions.

[0115] In certain embodiments, the insert may be symmetrical about a first axis.

[0116] In certain embodiments, the insert may be symmetrical about a second axis that extends in generally orthogonal relation to the first axis.

[0117] In certain embodiments, the post may include receptacles that are configured to slidably receive the insert.

[0118] In certain embodiments, the post may be fixedly connected to the base plate.

[0119] In certain embodiments, the post may define a first length, and the insert may define a second length that is less than the first length.

[0120] In certain embodiments, the post may define a first length, and the insert may define a second length that is approximately equal to the first length.

[0121] In another aspect of the present disclosure, a reinforced post assembly for a railing or fencing system is disclosed that includes: an insert; a post; and a base plate that indirectly connects the insert and the post. The insert includes a plurality of legs, and the post receives the insert such that the plurality of legs extend into the post.

[0122] In certain embodiments, the plurality of legs may be non-linear in configuration.

[0123] In certain embodiments, the plurality of legs may include first segments and second segments that extend from the first segments so as to define obtuse angles therebetween.

[0124] In certain embodiments, the post may include bosses that are configured to receive the plurality of legs.

[0125] In certain embodiments, the plurality of legs may include bulbous tips that are configured for insertion into the bosses to facilitate reception of the insert by the post and inhibit twisting of the insert during assembly of the reinforced post assembly.

[0126] In another aspect of the present disclosure, a reinforced post assembly for a railing or fencing system is disclosed that defines a longitudinal axis and includes: a base plate; a post that is connected to the base plate; a first insert; and a second insert. The first insert and the second insert are positioned within and mechanically engage the post and are configured as discrete components of the reinforced post assembly.

[0127] In certain embodiments, the post may include: a first boss; a second boss; a third boss; and a fourth boss.

[0128] In certain embodiments, the first boss, the second boss, the third boss, and the fourth boss may extend in generally parallel relation to the longitudinal axis.

[0129] In certain embodiments, the first insert may be configured for insertion into the first boss, the second boss, and the third boss.

[0130] In certain embodiments, the second insert may be configured for insertion into the fourth boss.

[0131] In certain embodiments, the first insert and the second insert may define a channel therebetween that is configured to receive a cable.

[0132] In certain embodiments, the first insert may include a first configuration, and the second insert may include a second configuration that is different than the first configuration.

[0133] While the present disclosure has been described in connection with certain embodiments, it is to be understood that the present disclosure is not to be limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation to encompass all such modifications and equivalent structures as is permitted under the law.

[0134] Persons skilled in the art will understand that the various embodiments of the present disclosure and shown in the accompanying figures constitute non-limiting examples, and that additional components and features may be added to any of the embodiments discussed hereinabove without departing from the scope of the present disclosure. Additionally, persons skilled in the art will understand that the elements and features shown or described in connection with one embodiment may be combined with those of another embodiment without departing from the scope of the present disclosure to achieve any desired result and will appreciate further features and advantages of the presently disclosed subject matter based on the description provided. Variations, combinations, and/or modifications to any of the embodiments and/or features of the embodiments described herein that are within the abilities of a person having ordinary skill in the art are also within the scope of the present disclosure, as are alternative embodiments that may result from combining, integrating, and/or omitting features from any of the disclosed embodiments.

[0135] Use of the term optionally with respect to any element of a claim means that the element may be included or omitted, with both alternatives being within the scope of the claim. Additionally, use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims that follow, and includes all equivalents of the subject matter of the claims.

[0136] In the preceding description, reference may be made to the spatial relationship between the various structures illustrated in the accompanying drawings, and to the spatial orientation of the structures. However, as will be recognized by those skilled in the art after a complete reading of this disclosure, the structures described herein may be positioned and oriented in any manner suitable for their intended purpose. Thus, the use of terms such as above, below, upper, lower, inner, outer, left, right, upward, downward, inward, outward, horizontal, vertical, etc., should be understood to describe a relative relationship between the structures and/or a spatial orientation of the structures. Those skilled in the art will also recognize that the use of such terms may be provided in the context of the illustrations provided by the corresponding figure(s).

[0137] Additionally, terms such as generally, approximately, substantially, and the like should be understood to include the numerical range, concept, or base term with which they are associated as well as variations in the numerical range, concept, or base term on the order of up to 25% (e.g., to allow for manufacturing tolerances and/or deviations in design). For example, the term generally parallel should be understood as referring to an arrangement in which the pertinent components (structures, elements) subtend an angle therebetween that is equal to 180 as well as an arrangement in which the pertinent components (structures, elements) subtend an angle therebetween that is greater than or less than 180 (e.g., 10%, 15%, 25%). The term generally parallel should thus be understood as encompassing configurations in which the pertinent components are arranged in parallel relation. Similarly, the term generally identical should be understood as encompassing configurations in which the pertinent components are identical in configuration as well as configurations in which there may be insubstantial variations between the pertinent components that do not influence the substantive construction or performance thereof.

[0138] Although terms such as first, second, third, etc., may be used herein to describe various operations, elements, components, regions, and/or sections, these operations, elements, components, regions, and/or sections should not be limited by the use of these terms in that these terms are used to distinguish one operation, element, component, region, or section from another. Thus, unless expressly stated otherwise, a first operation, element, component, region, or section could be termed a second operation, element, component, region, or section without departing from the scope of the present disclosure, etc.

[0139] Each and every claim is incorporated as further disclosure into the specification and represents embodiments of the present disclosure. Also, the phrases at least one of A, B, and C and A and/or B and/or C should each be interpreted to include only A, only B, only C, or any combination of A, B, and C.