Railing Systems Including Rail Assemblies With Integral Baluster Retention Members and Inserts

Abstract

A rail assembly that is configured to receive balusters. The rail assembly includes: an inner rail; an outer rail that is configured for connection to the inner rail; and an insert that is positioned within and which is directly supported by the outer rail such that, upon assembly of the rail assembly and insertion of the balusters, the insert is positioned laterally between the inner rail and the balusters.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 63 / 748,042, filed on Jan. 22, 2025, the entire contents of which are hereby incorporated by reference.TECHNICAL FIELD

[0002] The present disclosure relates to railing systems including rail assemblies that are configured to receive balusters.BACKGROUND

[0003] Railing systems generally include end posts, upper and lower rail assemblies, and balusters that extend between the upper and lower rail assemblies. During assembly and installation, the lower rail assembly is typically secured to the end posts, the balusters are inserted into openings in the lower rail assembly, and the upper rail assembly is then positioned and secured to the end posts. Positioning of the upper rail assembly, however, requires alignment of the balusters with corresponding openings, which is both cumbersome and time consuming.

[0004] The present disclosure addresses this shortcoming, among others, by providing a railing system with railing assemblies that simplify both assembly and installation.SUMMARY

[0005] The present disclosure describes a railing system including rail assemblies with a pass-through design that allows for insertion and placement of balusters after positioning of the rail assemblies. Each rail assembly includes: an inner rail; an outer rail; and an insert, which is (directly) supported by the outer rail and is positioned (located) laterally between the inner rail and the balusters. The inner rail and the insert include corresponding retention members such that, upon connection of the inner rail and the outer rail, the retention members on the insert are deflected and compressed into engagement (contact) with the balusters in order to clamp and automatically secure the balusters in place within the rail assembly.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. According to common practice and in the interest of clarity, certain components, elements, and / or features may be omitted from certain drawings.

[0007] FIG. 1 is a top, perspective view of a railing system in accordance with the principles of the present disclosure, which includes: (end) posts; caps for the posts; upper and lower rail assemblies that extend (horizontally) between the posts, each of which includes inner and outer rails; balusters that extend (vertically) between the rail assemblies; and bracket assemblies.

[0008] FIG. 2 is a partial, top, perspective view of the railing system shown with parts separated.

[0009] FIG. 3 is a partial, top, perspective view of the upper rail assembly illustrating the inner rail.

[0010] FIG. 4 is a partial, bottom, perspective view of the upper rail assembly illustrating the inner rail.

[0011] FIG. 5 is a partial, top, perspective view of the upper rail assembly illustrating the outer rail.

[0012] FIG. 6 is a partial, bottom, perspective view of the upper rail assembly illustrating the outer rail.

[0013] FIG. 7 is a (vertical) cross-sectional view taken along line 7-7 in FIG. 2 with the inner and outer rails shown prior to connection.

[0014] FIG. 8 is an enlargement of the area of detail identified in FIG. 7.

[0015] FIG. 9 is a (vertical) cross-sectional view of the inner and outer rails seen in FIG. 7 upon connection.

[0016] FIG. 10 is a (vertical) cross-sectional view taken along line 10-10 in FIG. 2 with the inner and outer rails shown prior to connection.

[0017] FIG. 11 is an enlargement of the area of detail identified in FIG. 10.

[0018] FIG. 12 is a (vertical) cross-sectional view of the inner and outer rails seen in FIG. 10 upon connection.

[0019] FIG. 13 is a partial, top, perspective view of an outer rail according to an alternate embodiment of the present disclosure.

[0020] FIG. 14 is a partial, top, perspective view illustrating one method of assembling the railing system.

[0021] FIG. 15 is a partial, top, perspective view illustrating an alternate method of assembling the railing system.

[0022] FIG. 16 is a top, perspective view of another railing system in accordance with the principles of the present disclosure, which includes an upper rail assembly and a lower rail assembly.

[0023] FIG. 17 is a partial, top, perspective view of the railing system seen in FIG. 16 shown with parts separated.

[0024] FIG. 18 is a (vertical) cross-sectional view of the upper rail assembly, which includes inner and outer rails and an insert, shown prior to connection of the inner and outer rails.

[0025] FIG. 19 is a (vertical) cross-sectional view of the upper rail assembly shown upon connection of the inner and outer rails.

[0026] FIG. 20 is a top, perspective view of the inner rail.

[0027] FIG. 21 is a top, perspective view of the outer rail.

[0028] FIG. 22 is a top, perspective view of the insert.

[0029] FIG. 23 is a (vertical) cross-sectional view of the lower rail assembly, which includes the inner rail seen in FIGS. 18-20, the insert seen in FIGS. 18, 19, and 22, and an outer rail, shown prior to connection of the inner rail and the outer rail.

[0030] FIG. 24 is a (vertical) cross-sectional view of the lower rail assembly shown upon connection of the inner and outer rails.

[0031] FIG. 25 is a top, perspective view of the outer rail of the lower rail assembly.

[0032] FIG. 26 is a top, perspective view of the outer rail of the lower rail assembly shown with an electrical component.

[0033] FIG. 27 is a partial, perspective view of the lower rail assembly shown during assembly.

[0034] FIG. 28 is a partial, perspective view of the lower rail assembly shown during connection of the inner and outer rails.

[0035] FIG. 29 is a partial, perspective view of the upper rail assembly shown during assembly.

[0036] FIG. 30 is a partial, perspective view illustrating insertion of the balusters into the lower rail assembly and the upper rail assembly.

[0037] FIG. 31 is a partial, perspective view of the upper rail assembly shown during connection of the inner and outer rails.

[0038] FIG. 32 is a (vertical) cross-sectional view of the upper rail assembly upon connection of the inner and outer rails.

[0039] FIG. 33 is a (vertical) cross-sectional view of the lower rail assembly upon connection of the inner and outer rails.DETAILED DESCRIPTION

[0040] With reference now to FIGS. 1 and 2, a railing (fencing) system 10 is disclosed that includes: (end) posts 100; caps 200 that are configured for connection to the posts 100; rail assemblies 300 (e.g., a lower rail assembly 300L and an upper rail assembly 300U) that extend (horizontally) between the posts 100; balusters 400 that extend (vertically) between the rail assemblies 300, each of which includes (first, lower and second, upper) ends 402, 404; and bracket assemblies 500 (e.g., respective lower and upper bracket assemblies 500L, 500U). Although a single panel (section of railing) 12 is illustrated in FIG. 1, it is envisioned that a plurality of panels 12 may be installed and arranged so as to define a rail (fence) line for use around a deck, a patio, a pool, to enclose a yard, etc.

[0041] Referring now to FIGS. 3-12 as well, the rail assemblies 300 will be discussed. The rail assemblies 300 are connected (secured) to the posts 100 via the bracket assemblies 500 and each define an overall (total) length L (FIG. 1), a width W, a height H, and a longitudinal (horizontal) axis X. The rail assemblies 300 receive (support) the balusters 400 and include respective inner and outer rails 302, 304, which are configured for connection, as described in further detail below.

[0042] In the illustrated embodiment, the lower rail assembly 300L and the upper rail assembly 300U are generally identical in configuration. As such, in the interest of brevity, only a single rail assembly 300 is discussed in the description that follows. Embodiments in which the lower rail assembly 300L and the upper rail assembly 300U may include non-identical configurations are also envisioned herein, however, as described in further detail below.

[0043] The inner rail 302 includes: an inner end 306; an outer end 308; a base wall 310; sidewalls 312; and (baluster) retention members 314.

[0044] The base wall 310 extends between and connects the sidewalls 312 and is generally planar (e.g., flat) in configuration. The base wall 310 includes apertures (openings) 316 (FIG. 4) that are configured to receive the balusters 400 such that the balusters 400 are insertable into the rail assembly 300 through the base wall 310.

[0045] The sidewalls 312 extend from the base wall 310 in generally orthogonal (perpendicular) relation so as to define corner portions 318 and include (inner, first) locking members 320 and fingers 322.

[0046] In the illustrated embodiment, the corner portions 318 are radiused in configuration. Embodiments in which the inner rail 302 is configured such that the corner portions 318 define right angles are also envisioned herein, however, as are embodiments in which the inner rail 302 is configured such that the corner portions 318 include a series of generally linear, interconnected segments.

[0047] The locking members 320 span the entire length L of the rail assembly 300 and extend laterally inward from the sidewalls 312 (e.g., towards a centerline C of the rail assembly 300 along the width W and in a direction that is generally orthogonal (perpendicular) in relation to the longitudinal axis X). The locking members 320 are configured for engagement (contact) with the outer rail 304, as described in further detail below, and are spaced from the base wall 310 by (vertical) distances V1 (FIGS. 8, 11), which extends in generally parallel relation to the height H of the rail assembly 300. The locking members 320 include locking surfaces 324 and (beveled, angled, chamfered) bearing surfaces 326, each of which is generally linear in configuration. More specifically, as seen in FIGS. 8, 11, the bearing surfaces 326 define transverse cross-sectional dimensions (e.g., widths) D1 that decrease towards the outer end 308 (FIG. 3) of the inner rail 302, thereby attributing tapered, generally triangular (vertical) cross-sectional configurations to the locking members 320.

[0048] The fingers 322 span the entire length L of the rail assembly 300 and are positioned (located) adjacent to (at) the outer end 308 (FIG. 3) of the inner rail 302. The fingers 322 are laterally inset along the width W of the rail assembly 300 (e.g., in relation to outermost surfaces 328 of the sidewalls 312) so as to define shoulders 330. As seen in FIGS. 7, 10, the fingers 322 are generally aligned with the locking members 320 along the width W of the rail assembly 300 and define (vertical) heights Hf that extend in generally parallel relation to the height H of the rail assembly 300 and correspond to (e.g., generally approximate, mirror) the distances V1 (FIGS. 8, 11).

[0049] The retention members 314 span the entire length L of the rail assembly 300 and are integrally (monolithically) formed with the inner rail 302. The retention members 314 extend (directly) from the base wall 310 toward the outer end 308 (FIG. 3) of the outer rail 304 in generally orthogonal (perpendicular) relation to the longitudinal axis X of the rail assembly 300.

[0050] The retention members 314 are configured as a (first) set of prongs 332 and each include: a root 334, which is generally linear in configuration and is connected (secured) to the base wall 310; a belly 336, which extends from the root 334 and includes (defines) an arcuate configuration with a curvature that extends in a first direction; and a tip 338, which extends from the belly 336 and includes (defines) an arcuate configuration with a curvature that extends in a second direction that is opposite to the first direction. More specifically, as seen in FIGS. 7, 10, the belly 336 includes a convex curvature that curves towards the centerline C of the rail assembly 300 so as to facilitate engagement (contact) with the balusters 400, and the tip 338 includes a concave curvature that curves away from the centerline C so as to facilitate engagement (contact) with the outer rail 304, as descried in further detail below.

[0051] With specific reference to FIGS. 7-12, during (upon) connection of the rails 302, 304, the retention members 314 are repositionable between a normal (first, initial) position (FIGS. 7, 10) and a deflected (second, subsequent) position (FIGS. 9, 12). In the normal position, the retention members 314 are separated (spaced apart) by a first (lateral) distance, which facilitates insertion of the balusters 400 into the inner rail 302 (e.g., via the apertures 316), and in the deflected position, the retention members 314 are separated (spaced apart) by a second (lateral) distance, which is less than the first distance and facilitates engagement (contact) between the retention members 314 and the balusters 400 to thereby secure the balusters 400 in place within the rail assembly 300. More specifically, during (upon) connection of the rails302, 304, the retention members 314 are deflected laterally inward (e.g., towards each other and the centerline C of the rail assembly 300) along an axis of deflection Y (FIG. 9) that extends in generally parallel relation to the width W of the rail assembly 300 and in generally orthogonal (perpendicular) relation to the longitudinal axis X. Upon deflection, the retention members 314 are compressed into engagement (contact) with the balusters 400, which clamps and automatically secures the balusters 400 within the rail assembly 300 without the use of fasteners, an adhesive, etc.

[0052] The outer rail 304 includes: an inner end 340 (FIGS. 5, 6), which extends into the inner rail 302; an outer end 342; an outer wall 344; sidewalls 346; a crossbeam 348; and deflectors 350.

[0053] The outer wall 344 extends between and connects the sidewalls 346. In the embodiment illustrated in FIGS. 1-12, the outer wall 344 is generally planar (e.g., flat) in configuration. FIG. 13 illustrates an alternate embodiment of the outer rail 304, however, which includes an outer wall 352 that is non-planar in configuration. More specifically, outer wall 352 includes a convex curvature, which inhibits (e.g., prevents) the pooling of water and deters a user from resting items (e.g., beverage containers, glasses, bottles, etc.) on the rail assembly 300.

[0054] The sidewalls 346 extend from the outer wall 344 in generally orthogonal (perpendicular) relation so as to define corner portions 354 and include (outer, second) locking members 356 and receptacles 358.

[0055] In the illustrated embodiment, the corner portions 354 are radiused in configuration. Embodiments in which the outer rail 304 is configured such that the corner portions 354 define right angles are also envisioned herein, however, as are embodiments in which the outer rail 304 is configured such that the corner portions 354 include a series of generally linear, interconnected segments.

[0056] The locking members 356 span the entire length L of the rail assembly 300 and extend laterally outward from the sidewalls 346 (e.g., away from each other in generally parallel relation to the width W of the rail assembly 300 and in a direction that is generally orthogonal (perpendicular) in relation to the longitudinal axis X). The locking members 356 are generally identical in configuration to the locking members 320 on the inner rail 302 and are configured for engagement (contact) therewith, as described in further detail below. As such, the locking members 356 include locking surfaces 360 and (beveled, angled, chamfered) bearing surfaces 362, each of which is generally linear in configuration. More specifically, as seen in FIGS. 8, 11, the bearing surfaces 362 define transverse cross-sectional dimensions (e.g., widths) D2, which are generally identical to the transverse cross-sectional dimensions D1 and increase towards the outer end 342 (FIGS. 5, 6) of the outer rail 304, thereby attributing tapered, generally triangular (vertical) cross-sectional configurations to the locking members 356.

[0057] As seen in FIGS. 8 and 11, during approximation of the rails 302, 304, the bearing surfaces 326, 362 are brought into engagement (contact), which deflects the sidewalls 312 on the inner rail 302 (e.g., laterally outward, away from each other along the width W of the rail assembly 300) and / or the sidewalls 346 on the outer rail 304 (e.g., laterally inward, towards each other along the width W of the rail assembly 300). As seen in FIGS. 9 and 12, upon connection of the rails 302, 304, the locking surfaces 324, 360 are brought into engagement (contact), which resists the vertical forces that are applied to the rails 302, 304 via engagement (contact) between the retention members 314 and the deflectors 350, which is discussed in further detail below, thereby inhibiting (e.g., preventing) unintended separation of the rails 302, 304.

[0058] In certain embodiments, it is envisioned that the locking members 320, 356 may be configured to provide tactile and / or audible indications of proper connection of the rails 302, 304.

[0059] The receptacles 358 span the entire length L of the rail assembly 300 and are generally aligned with the fingers 322 on the inner rail 302 along the width W of the rail assembly 300. As seen in FIGS. 7, 10, the receptacles 358 define (vertical) heights Hr that extend in generally parallel relation to the height H of the rail assembly 300 and correspond to (e.g., generally approximate, mirror) the heights Hf defined by the fingers 322 and the distances V1 (FIGS. 8, 11). The receptacles 358 are laterally inset along the width W of the rail assembly 300 (e.g., in relation to outermost surfaces 364 of the sidewalls 346) and are configured to receive the fingers 322 in order to inhibit (e.g., prevent) relative lateral movement between the rails 302, 304 upon connection (e.g., rattle).

[0060] The crossbeam 348 spans the entire length L of the rail assembly 300 and is spaced from the outer wall 344 along the height H of the rail assembly 300. The crossbeam 348 extends between the sidewalls 346, thereby increasing the strength (rigidity) of the outer rail 304, and supports the deflectors 350. The crossbeam 348 includes a recess 366 (FIGS. 5, 6), which extends towards the outer wall 344 and is configured to receive the balusters 400. Receipt of the balusters 400 within the recess 366 not only facilitates proper insertion and alignment of the balusters 400 but stabilizes the balusters 400 by inhibiting (e.g., preventing) relative lateral movement between the balusters 400 and the rails 302, 304 upon connection (e.g., rattle).

[0061] The deflectors 350 span the entire length L of the rail assembly 300 and are integrally (monolithically) formed with the outer rail 304. The deflectors 350 extend (directly) from the crossbeam 348 toward the inner end 340 (FIGS. 5, 6) of the outer rail 304 (and the inner rail 302) in generally orthogonal (perpendicular) relation to the longitudinal axis X of the rail assembly 300. More specifically the deflectors 350 are positioned (located) laterally outward of the recess 366 and are generally aligned with the retention members 314 along the width W of the rail assembly 300, which facilitates engagement (contact) between the retention members 314 and the deflectors 350 during (upon) connection of the rails 302, 304, as described in further detail below.

[0062] The deflectors 350 are configured as a (second) set of prongs 368 and include posts 370, which are generally linear in configuration and are connected (secured) to the crossbeam 348, and (beveled, angled, chamfered) bearing surfaces 372, which extend laterally inward from the posts 100 (e.g., towards each other) along the width W of the rail assembly 300. The bearing surfaces 372 are configured for engagement (contact) with the tips 338 of the retention members 314 upon connection of the rails 302, 304 and are generally linear in configuration. More specifically, as seen in FIGS. 8, 11, the bearing surfaces 372 define transverse cross-sectional dimensions (e.g., widths) D3 that increase towards the outer end 342 (FIGS. 5, 6) of the outer rail 304, thereby attributing tapered, generally triangular (vertical) cross-sectional configurations to the deflectors 350 and facilitating both connection of the rails 302, 304 and engagement (contact) with the retention members 314.

[0063] As seen in FIGS. 7-12, during (upon) connection of the rails 302, 304, the deflectors 350 engage (contact) the retention members 314, which displaces the retention members 314 laterally inward (e.g., towards each other along the width W of the rail assembly 300) as the retention members 314 are repositioned from the normal position (FIGS. 7, 10) into the deflected position (FIGS. 9, 12), thereby applying a compressive force to the balusters 400 and clamping the balusters 400 within the rail assembly 300.

[0064] The rails 302, 304 are each unitary (monolithic) in construction and are each extruded from a single piece of resilient (flexible), metallic material (e.g., aluminum, steel, etc.). Embodiments in which the rail 302 and / or the rail 304 are non-unitary in construction are also envisioned herein, however, as are embodiments in which alternate methods of manufacture are utilized.

[0065] The construction and the flexibility of the rails 302, 304 facilitates resilient repositioning of the retention members 314 between the normal and deflected positions as well as resilient deflection of the sidewalls 312, 346 during approximation and connection of the rails 302, 304. The resilient construction of the rails 302, 304 also biases the retention members 314 laterally outward (e.g., away from each other along the width W of the rail assembly 300) such that the retention members 314 automatically return to the normal position upon separation of the rails 302, 304 and facilitates return of the sidewalls 312, 346 to the normal positions seen in FIGS. 7-12.

[0066] The bracket assemblies 500 (FIG. 2) support and indirectly connect the rail assemblies 300 to the posts 100. The bracket assemblies 500 include: (saddle) brackets 502; fasteners 504, 506; and covers 508.

[0067] The brackets 502 define chambers 510 that are configured to receive the rail assemblies 300 such that the rail assemblies 300 extend into the brackets 502. The brackets 502 include: a base wall 512; sidewalls 514, which extend (vertically) from the base wall 512 in generally orthogonal (perpendicular) relation thereto; and an end wall 516, which extends between and connects the base wall 512 and the sidewalls 514. More specifically, the end wall 516 extends (vertically) from the base wall 512 and (horizontally) between the sidewalls 514 and in generally orthogonal (perpendicular) relation thereto.

[0068] The fasteners 504, 506 connect the brackets 502 to the posts 100 and the rail assemblies 300. More specifically, the fasteners 504 extend into the posts 100 through the end walls 516, and the fasteners 506 extend into the rail assemblies 300 through the base walls 512 and the sidewalls 514.

[0069] The covers 508 are configured for removable engagement with (connection to) the brackets 502 in order to conceal the fasteners 504, 506. In the illustrated embodiment, the covers 508 are configured to engage (contact) the brackets 502 in an interference (pressure) fit, thereby obviating any need for additional fasteners, an adhesive, etc. It is envisioned, however, that the covers 508 and the brackets 502 may be configured for engagement (contact) in any suitable manner.

[0070] With reference now to FIGS. 1-12, 14, and 15, various methods of assembling the railing system 10 will be discussed. In contrast to known systems, the railing system 10 and the methods of assembly described herein simplify insertion of the balusters 400 by reducing (if not entirely eliminating) the need to align the balusters 400 with the apertures 316, which obviates the need for the templates and the tools typically required for the installation of known railing systems as well as preassembly of the panel(s) 12.

[0071] Referring to FIGS. 1-12 and 14 in particular, in one method of assembling and installing the railing system 10, following placement of the posts 100, the bracket assemblies 500 (FIG. 2) are connected thereto via the fasteners 504. The lower rail assembly 300L is then partially assembled (FIGS. 9, 10) by positioning the rails 302, 304 thereof in contact such that the locking members 320, 356 (e.g., the bearing surfaces 326, 362) are in adjacent relation. The lower rail assembly 300L is then inserted into the lower bracket assemblies 500L (e.g., the chambers 510 defined by the brackets 502) partially assembled.

[0072] Thereafter, the inner rail 302 of the upper rail assembly 300U is inserted into the upper bracket assemblies 500U (e.g., the chambers 510 defined by the brackets 502), and the balusters 400 are inserted through the inner rails 302 of the upper rail assembly 300U and the inner rail 304 of the lower rail assembly 300L (via the apertures 316) such that the ends 402 of the balusters 400 are seated within the recess 366 in the outer rail 304 of the lower rail assembly 300L. The pass-through design of the rail assemblies 300 thus allows for insertion and placement of the balusters 400 after positioning of the rail assemblies 300 in relation to the posts 100 (e.g., via insertion into the bracket assemblies 500).

[0073] Following insertion of the balusters 400, the upper rail assembly 300U is partially assembled (FIGS. 7, 8) by positioning the rails 302, 304 thereof in contact such that the locking members 320, 356 (e.g., the bearing surfaces 326, 362) are in adjacent relation. Assembly of the upper rail assembly 300U and the lower rail assembly 300L is then completed via approximation of the rails 302, 304 along axes of movement M (FIGS. 9, 12), which extends in generally orthogonal (perpendicular) relation to the width W of the upper rail assembly 300U and the lower rail assembly 300L, the longitudinal axes L, and the axes of deflection Y.

[0074] During approximation of the rails 302, 304, the retention members 314 are repositioned from the normal position (FIGS. 7, 10) into the deflected position (FIGS. 9, 12), thereby compressing and clamping the balusters 400 in order to secure the balusters 400 within the lower rail assembly 300L and the upper rail assembly 300U.

[0075] The fasteners 506 (FIG. 2) are then inserted through the brackets 502 and into the lower rail assembly 300L and the upper rail assembly 300U, thereby (indirectly) connecting (securing) the lower rail assembly 300L and the upper rail assembly 300U to the posts 100.

[0076] The caps 200 and the covers 508 are then placed in order to complete assembly of the railing system 10.

[0077] Referring now to FIGS. 1-12 and 15, an alternate method of assembling and installing the railing system 10 will be discussed.

[0078] Following placement of the posts 100 and connection of the bracket assemblies 500 thereto, the inner rails 302 of the lower rail assembly 300L and the upper rail assembly 300U are positioned in back-to-back relation such that the base walls 310 thereof are in adjacent (e.g., contacting) relation and the apertures 316 are aligned, as seen in FIG. 15. The balusters 400 are then inserted through the inner rails 302 (via the apertures 316) and the inner rails 302 are (vertically) separated (e.g., by sliding the inner rails 302 along the balusters 400) such that the inner rail 302 of the lower rail assembly 300L is positioned adjacent to (at) the ends 402 of the balusters 400 and the inner rail 302 of the upper rail assembly 300U is positioned adjacent to (at) the ends 404 of the balusters 400.

[0079] The outer rails 304 are then brought into engagement (contact) with the inner rails 302, as seen in FIGS. 7 and 10, and the lower rail assembly 300L and the upper rail assembly 300U are assembled via approximation of the rails 302, 304 along the axes of movement M, as discussed above, thereby repositioning the retention members 314 from the normal position (FIGS. 7, 10) into the deflected position (FIGS. 9, 12).

[0080] The lower rail assembly 300L and the upper rail assembly 300U are then inserted into the bracket assemblies 500L, 500U (e.g., the chambers 510 defined by the brackets 502), respectively, the fasteners 506 are inserted through the brackets 502 and into the lower rail assembly 300L and the upper rail assembly 300U, and the caps 200 and the covers 508 are placed.

[0081] With reference now to FIGS. 16 and 17, a railing (fencing) system 20 is disclosed that includes: the posts 100; the caps 200; the balusters 400; the bracket assemblies 500; and an upper rail assembly 600 and a lower rail assembly 700, which are connected (secured) to the posts 100 via the bracket assemblies 500. The upper rail assembly 600 and the lower rail assembly 700 are alternate embodiments of the rail assemblies 300 (FIGS. 1-15) discussed above and include similar components and features. Accordingly, the upper rail assembly 600 and the lower rail assembly 700 will only be discussed with respect to differences from the rail assemblies 300 in the interest of brevity. As such, identical reference characters will be utilized to refer to elements, structures, features, etc., that are common to the rail assemblies 300, the upper rail assembly 600, and the lower rail assembly 700.

[0082] Referring now to FIGS. 18-22 as well, the upper rail assembly 600 includes respective inner and outer rails 602, 604, which are configured for connection, as described in further detail below, as well as an insert 606 (which may also be referred to as a compression insert).

[0083] The inner rail 602 (FIG. 20) includes a base wall 608 and retention members 610 (which may also be referred to as first retention members).

[0084] The base wall 608 s generally planar (e.g., flat) in configuration and includes opposite ends 612, 614 as well as the apertures 316, which receive the balusters 400 such that the balusters 400 are insertable into the upper rail assembly 600 through the base wall 608, as discussed above.

[0085] The retention members 610 span the entire length L (FIG. 16) of the upper rail assembly 600 and are integrally (monolithically) formed with the inner rail 602 (e.g., from single piece of metallic material). The retention members 610 extend (directly) from the base wall 608 in non-orthogonal (non-perpendicular) relation thereto (e.g., towards the outer rail 604) and are spaced laterally inward from the opposite ends 612, 614 thereof so as to define shoulders 616. More specifically, the retention members 610 extend from the base wall 608 so as to define acute angles α.

[0086] In the illustrated embodiment, the inner rail 602 is configured such that the angles α lie substantially within the range of approximately 60 degrees to approximately 80 degrees. Embodiments in which the inner rail 602 is configured such that the angles α lie substantially outside of the disclosed range are also envisioned herein, however (e.g., in order to vary the force required to connect the inner rail 602 and the outer rail 604).

[0087] The retention members 610 include inner bearing surfaces 618 (which may also be referred to as first bearing surfaces) and locking members 620, which extend laterally inward (e.g., towards each other and the centerline C (FIG. 18) along the width W of the upper rail assembly 600) and span the entire length L of the upper rail assembly 600. The locking members 620 are configured for engagement (contact) with the outer rail 604 and include locking surfaces 622 and outer bearing surfaces 624 (which may also be referred to as second bearing surfaces), each of which is generally linear in configuration. The locking members 620 include tapered configurations and define transverse cross-sectional dimensions (e.g., widths) that decrease towards the outer rail 604, which facilitates engagement (contact) between the locking members 620 and the outer rail 604, as described in further detail below.

[0088] During (upon) connection of the inner rail 602 and the outer rail 604, the retention members 610 are repositionable between normal (first, initial) positions and deflected (second, subsequent) positions. Prior to connection of the inner rail 602 and the outer rail 604, in the normal positions (FIG. 18), the retention members 610 are separated (spaced apart) by a first (lateral) distance, which facilitates insertion of the balusters 400 into the inner rail 602 (e.g., via the apertures 316) as well as assembly of the upper rail assembly 600. Upon connection of the inner rail 602 and the outer rail 604, however, in the deflected positions (FIG. 19), the retention members 610 are separated (spaced apart) by a second (lateral) distance, which is less than the first distance and facilitates securement of the balusters 400 in place within the upper rail assembly 600, as described in further detail below. More specifically, during (upon) connection of the inner rail 602 and the outer rail 604, the retention members 610 are deflected laterally inward (e.g., towards each other and the centerline C of the upper rail assembly 600) along the axis of deflection Y, which extends in generally parallel relation to the width W of the upper rail assembly 600. Upon deflection, the retention members 610 (e.g., the inner bearing surfaces 618) are compressed into engagement (contact) with the insert 606, which clamps and automatically secures the balusters 400 within the upper rail assembly 600 without the use of fasteners, an adhesive, etc., as described in further detail below.

[0089] The outer rail 604 includes: an outer wall 626; sidewalls 628, which extend from the outer wall 626 in generally orthogonal (perpendicular) relation; a crossbeam 630; base walls 632; and deflectors 634.

[0090] The outer wall 626 extends between and connects the sidewalls 628. In the illustrated embodiment, the outer wall 626 includes a convex curvature, which inhibits (e.g., prevents) the pooling of water and deters a user from resting items (e.g., beverage containers, glasses, bottles, etc.) on the upper rail assembly 600. Embodiments in which the outer wall 626 is generally planar (e.g., flat) in configuration are also envisioned herein, however (e.g., depending upon the desired aesthetic of the railing system 20).

[0091] The crossbeam 630 spans the entire length L (FIG. 16) of the upper rail assembly 600 and is spaced from the outer wall 626 along the height H. The crossbeam 630 extends between the sidewalls 628, thereby increasing the strength (rigidity) of the outer rail 604. The crossbeam 630 includes a channel 636 (FIG. 18. 21), which extends vertically into the crossbeam 630 (e.g., towards the outer wall 626) and is configured to slidably receive the insert 606, as described in further detail below. The channel 636 includes a generally T-shaped cross-sectional configuration, which defines flanges 638 that are configured for engagement (contact) with the insert 606, as described in further detail below, in order to inhibit (e.g., prevent) inadvertent separation of the outer rail 604 and the insert 606 and thereby maintain assembly of the upper rail assembly 600.

[0092] In the illustrated embodiment, the crossbeam 630 includes a notch 640 that extends vertically from the crossbeam 630 (e.g., towards the outer wall 626). The notch 640 is in communication with the channel 636 and receives the insert 606 in order to inhibit (e.g., prevent) unintended relative (vertical) movement between the outer rail 604 and the insert 606. Embodiments of the outer rail 604 that are devoid of the notch 640 are also envisioned herein, however.

[0093] The base walls 632 extend laterally inward from the sidewalls 628 and support the deflectors 634. The base walls 632 define recesses 642 (FIG. 18), which are configured to receive the shoulders 616 on the inner rail 602 such that the base wall 608 of the inner rail 602 is received by (e.g., is nested within) the base walls 632 of the outer rail 604. More specifically, upon connection of the inner rail 602 and the outer rail 604, the recesses 642 receive the shoulders 616 such that a bottom surface 644 of the inner rail 602 (which may also be referred to as a lowermost surface of the inner rail 602) is generally flush (e.g., coplanar) with a bottom surface 646 of the outer rail 604 (which may also be referred to as a lowermost surface of the outer rail 604), as seen in FIG. 19.

[0094] The deflectors 634 span the entire length L (FIG. 16) of the upper rail assembly 600 and are integrally (monolithically) formed with the outer rail 604 (e.g., from single piece of metallic material). The deflectors 634 are generally aligned with the recesses 642 and extend (directly) from the base walls 632 towards the crossbeam 630.

[0095] The deflectors 634 are configured for engagement (contact) with the retention members 610 (e.g., the outer bearing surfaces 624 on the locking members 620) during (upon) connection of the inner rail 602 and the outer rail 604, as described in further detail below. The deflectors 634 include bearing surfaces 648 (FIGS. 18, 21) and heads 650 that define locking surfaces 652.

[0096] The heads 650 include tapered configurations and define transverse cross-sectional dimensions (e.g., widths) that decrease towards the crossbeam 630, which facilitates engagement (contact) between the locking surfaces 652 and the locking surfaces 622 on the locking members 620 during approximation and connection of the inner rail 602 and the outer rail 604, as described in further detail below.

[0097] The deflectors 634 are configured such that the bearing surfaces 648 define obtuse angles β (FIG. 18) with the base walls 632 and extend in generally parallel relation to the outer bearing surfaces 624 (FIGS. 19, 20) on the locking members 620. In the illustrated embodiment, the outer rail 604 is configured such that the angles β lie substantially within the range of approximately 100 degrees to approximately 130 degrees. Embodiments in which the outer rail 604 is configured such that the angles β lie substantially outside of the disclosed range are also envisioned herein, however (e.g., in order to vary the force required to connect the inner rail 602 and the outer rail 604).

[0098] As seen in FIGS. 18 and 19, during approximation of the inner rail 602 and the outer rail 604, the outer bearing surfaces 624 on the retention members 610 and the bearing surfaces 648 on the deflectors 634 are brought into engagement (contact), which deflects the retention members 610 laterally inward (e.g., towards each other and the centerline C of the upper rail assembly 600). Embodiments in which the deflectors 634 are deflected laterally outward (e.g., away from each other) during approximation of the inner rail 602 and the outer rail 604 are also envisioned herein, however, as are embodiments in which the deflectors 634 remain fixed (e.g., depending upon the particular material(s) of construction used in fabrication of the outer rail 604).

[0099] The insert 606 (FIG. 22) is configured to receive and engage (contact) the balusters 400 and includes a body 654 and a foot 656 that extends from the body 654. More specifically, the insert 606 is configured to receive the balusters 400 such that the balusters 400 extend inwardly into the insert 606, as seen in FIGS. 18 and 19 and described in further detail below.

[0100] The insert 606 is positioned within and is directly supported by the outer rail 604 such that, upon assembly of the upper rail assembly 600 and insertion of the balusters 400, the insert 606 is positioned laterally between the inner rail 602 (e.g., the retention members 610) and the balusters 400 (e.g., along the width W of the upper rail assembly 600), as seen in FIGS. 18 and 19, thereby separating the retention members 610 and the balusters 400 and inhibiting (e.g., preventing) engagement (contact) therebetween.

[0101] As discussed in further detail below, upon connection of the inner rail 602 and the outer rail 604, the insert 606 is subject to a compressive force, which is applied to the balusters 400 in order to clamp and fixedly (e.g., non-movably) secure the balusters 400 within the upper rail assembly 600, thereby inhibiting (e.g., preventing) unintended relative movement between the insert 606 and the inner rail 602 (e.g., rattle). Positioning of the insert 606 laterally between the inner rail 602 and the balusters 400 thus reduces the deflection of the inner rail 602 required in order to secure the balusters 400, thereby alleviating manufacturing tolerances in the inner rail 602 (and the outer rail 604).

[0102] The body 654 includes a backspan 658 and retention members 660 (which may also be referred to as second retention members), each of which spans the entire length L (FIG. 16) of the upper rail assembly 600. The insert 606 is unitary (monolithic) in construction. As such, the foot 656, the backspan 658, and the retention members 660 are integrally formed from a single piece of resilient (flexible) material.

[0103] In the illustrated embodiment, the insert 606 is formed from a non-metallic material (e.g., PVC). The inner rail 602 and the outer rail 604 are thus formed from a first material (e.g., aluminum, steel, etc.), and the insert 606 is formed from a second, different material. Embodiments in which the insert 606 includes one or more different materials (e.g., one or more metallic materials) are also envisioned herein, however (e.g., to increase the usable life of the insert 606, such that the inner rail 602, the outer rail 604, and the insert 606 are formed from a common material, etc.).

[0104] The backspan 658 is generally planar (e.g., flat) in configuration and extends in generally parallel relation to the width W of the of the upper rail assembly 600, the base wall 608 of the inner rail 602, and the crossbeam 630 of the outer rail 604. The backspan 658 extends between and connects the retention members 660 such that the body 654 includes a generally U-shaped cross-sectional configuration defining a chamber 662, which receives the balusters 400 and is collectively defined by the backspan 658 and the retention members 660. The inner rail 602 and the insert 606 thus insulate the balusters 400 such that the balusters 400 are devoid of direct engagement (contact) with the outer rail 604.

[0105] The retention members 660 are non-linear in configuration and are configured for engagement (contact) with the inner rail 602 (e.g., the retention members 610) and the balusters 400, as described in further detail below. The retention members 660 extend (directly) from the backspan 658 in a first direction (e.g., towards the inner rail 602) in generally orthogonal (perpendicular) relation to the length L and the width W of the upper rail assembly 600.

[0106] The retention members 660 include: roots 664 (which may also be referred to as first segments), which are generally linear in configuration and are connected (secured) to the backspan 658; bellies 666 (which may also be referred to as second segments and individually as a belly), which extend from the roots 664; and tips 668 (which may also be referred to as third segments).

[0107] The bellies 666 extend from the roots 664 and include (define) arcuate configurations with curvatures that extend in first directions. More specifically, as seen in FIG. 18, the bellies 666 include convex curvatures that extend laterally inward (e.g., towards the centerline C of the upper rail assembly 600).

[0108] The tips 668 extend laterally inward from the bellies 666 (e.g., towards the centerline C of the upper rail assembly 600) and include bearing surfaces 670. More specifically, the retention members 660 are configured such that the tips 668 extend from the bellies 666 so as to define obtuse angles γ (FIG. 18).

[0109] In the illustrated embodiment, the retention members 660 are configured such that the angles γ lie substantially within the range of approximately 110 degrees to approximately 150 degrees. Embodiments in which the retention members 660 are configured such that the angles γ lie substantially outside of the disclosed range are also envisioned herein (e.g., in order to vary the force required to connect the inner rail 602 and the outer rail 604).

[0110] Although shown as being generally linear in configuration, embodiments in which the tips 668 may include non-linear configurations are also envisioned herein. For example, as discussed above in connection with the retention members 314 (FIGS. 3, 4) of the rail assembly 300, it is envisioned that the tips 668 may include (define) arcuate configurations with curvatures that extend in second directions that are opposite to the first directions.

[0111] **During (upon) connection of the inner rail 602 and the outer rail 604, the retention members 660 are repositionable between normal (first, initial) positions and deflected (second, subsequent) positions. Prior to connection of the inner rail 602 and the outer rail 604, in the normal positions (FIG. 18), the retention members 660 are separated (spaced) apart by a first (lateral) distance, which facilitates insertion of the balusters 400 into the inner rail 602 (e.g., via the apertures 316) as well as assembly of the upper rail assembly 600. Upon connection of the inner rail 602 and the outer rail 604, however, in the deflected positions (FIG. 19), the retention members 660 are separated (spaced) apart by a second (lateral) distance, which is less than the first distance and facilitates securement of the balusters 400 in place within the upper rail assembly 600. More specifically, during (upon) connection of the inner rail 602 and the outer rail 604, the retention members 610 (e.g., the inner bearing surfaces 618) are deflected into engagement (contact) with the tips 668 (e.g., the bearing surfaces 670), which deflects the retention members 660 laterally inward (e.g., towards each other and the centerline C of the upper rail assembly 600) along the axis of deflection Y. Upon deflection, the retention members 660 (e.g., the bellies 666) are compressed into engagement (contact) with the balusters 400, thereby applying the aforementioned compressive force to the balusters 400, which clamps and automatically secures the balusters 400 within the upper rail assembly 600 without the use of fasteners, an adhesive, etc., as indicated above.

[0112] The non-linear configurations of the retention members 660 not only facilitate simultaneous engagement (contact) of the insert 606 with the balusters 400 and the inner rail 602 but increase the compressive force that is applied to the balusters 400 as well as the surface area that is in contact with the balusters 400. Embodiments in which the retention members 660 are generally linear in configuration are also envisioned herein, however (e.g., in order to reduce manufacturing complexity). In such embodiments, it is envisioned that the retention members 660 may include one or more detents, ribs, protrusions, or other such projections that extend laterally inward therefrom in order to facilitate engagement (contact) with the balusters 400 in the manner described herein.

[0113] The foot 656 is configured for insertion into the outer rail 604 (e.g., the channel 636 in the crossbeam 630) and spans the entire length L of the upper rail assembly 600. The foot 656 extends from the backspan 658 in a second direction (e.g., away from the inner rail 602) that is generally opposite to the first direction (e.g., such that the retention members 660 and the foot 656 extend in generally opposite directions) and in generally orthogonal (perpendicular) relation to the length L and the width W of the upper rail assembly 600.

[0114] The foot 656 includes a generally T-shaped cross-sectional configuration and includes a trunk 672, which extends from the backspan 658 in generally orthogonal (perpendicular) relation, and a crossmember 674, which extends from the trunk 672 in generally orthogonal (perpendicular) relation and in generally parallel relation to the backspan 658 and the width W of the upper rail assembly 600. More specifically, the crossmember 674 extends laterally outward from the trunk 672 so as to define reliefs 678, which receive the flanges 638 on the crossbeam 630 such that the flanges 638 extend laterally into the insert 606, as seen in FIG. 18, thereby securing the insert 606 within the outer rail 604 (e.g., the channel 636).

[0115] With reference now to FIGS. 23-25, the lower rail assembly 700 will be discussed. The lower rail assembly 700 is substantially similar to the upper rail assembly 600 and, accordingly, will only be discussed with respect to differences therefrom in the interest of brevity. As such, identical reference characters will be utilized to refer to elements, structures, features, etc., that are common to the upper rail assembly 600 and the lower rail assembly 700. Embodiments in which the upper rail assembly 600 and the lower rail assembly 700 include identical configurations, however, are also envisioned herein (e.g., depending upon the requirements of the particular installation for the railing system 20).

[0116] In addition to the inner rail 602 and the insert 606, the lower rail assembly 700 includes an outer rail 704. The outer rail 704 includes: the sidewalls 628; the crossbeam 630; the base walls 632; the deflectors 634; and an outer wall 726. The outer rail 704 is identical to the outer rail 604 (FIGS. 18-22) included on the upper rail assembly 600 but for the inclusion of a channel 780 in the outer wall 726.

[0117] The channel 780 is configured to receive (one or more) at least one support member 800 (FIG. 16) (e.g., a footing 802) fort the railing system 20, which lends additional support to the lower rail assembly 700 and the panels 12 (FIGS. 1, 16), and / or an electrical component 900 (FIG. 26) (e.g., LED lighting 902, wiring, conduits, etc.).

[0118] The channel 780 spans the entire length L of the lower rail assembly 700 and extends vertically into the outer wall 726 (e.g., towards the inner rail 602). The channel 780 includes a generally T-shaped cross-sectional configuration that defines flanges 782, which are configured for engagement (contact) with the support member(s) 800.

[0119] In the illustrated embodiment, the outer wall 726 further includes a notch 784 (FIG. 25), which extends vertically into an inner wall 786 defined by the channel 780 (e.g., towards the inner rail 602). The notch 784 is in communication with the channel 780 and is configured to receive and create additional clearance for the support member(s) 800 and the electrical component 900 (e.g., in order to facilitate the integration of the electrical component 900 into the panels 12).

[0120] With reference now to FIGS. 16-22 and 27-33, various methods of assembling the railing system 20 (FIG. 16) (e.g., the upper rail assembly 600 and the lower rail assembly 700) and installing the railing system 20 will be discussed. The methods described below are similar to those discussed above with respect to the railing system 10 (FIGS. 1-15) and, accordingly, will only be discussed with respect to differences therefrom in the interest of brevity.

[0121] Following placement of the posts 100 (FIGS. 16, 17) and the bracket assemblies 500, which may be pre-mounted thereto, the lower rail assembly 700 is partially assembled. More specifically, the insert 606 is slidably inserted into the channel 636 in the crossbeam 630, as seen in FIG. 27, and the outer rail 604 is positioned within the brackets 502 of the lower bracket assemblies 500L together with the insert 606, as seen in FIG. 28. The support member(s) 800 are then inserted into the channel 780 in the outer wall 726, and, if necessary, the support member(s) 800 are cut to the length. The inner rail 602 is then positioned adjacent to (e.g., atop) the outer rail 604 and the insert 606 such that the outer bearing surfaces 624 (FIGS. 18, 20) on the locking members 620 engage (contact) the bearing surfaces 648 (FIGS. 18, 21) on the deflectors 634.

[0122] Thereafter, the inner rail 602 on the upper rail assembly 600 is inserted into the brackets 502 of the upper bracket assemblies 500U, as seen in FIG. 29, and the balusters 400 are inserted through the inner rail 602 on the upper rail assembly 600 and the inner rail 602 on the lower rail assembly 700 via the apertures 316 (FIGS. 20, 28), as seen in FIG. 30, such that the balusters 400 extend into the chamber 662 (FIGS. 18, 20) in each inner rail 602.

[0123] Following insertion of the balusters 400, the insert 606 is slidably inserted into the channel 636 in the crossbeam 630 of the outer rail 604 on the upper rail assembly 600, as seen in FIG. 31, and the outer rail 604 is positioned adjacent to (e.g., atop) the inner rail 602 together with the insert 606 such that the outer bearing surfaces 624 (FIGS. 19, 20) on the locking members 620 engage (contact) the bearing surfaces 648 (FIGS. 18, 21) on the deflectors 634.

[0124] With reference to FIGS. 32 and 33, assembly of the upper rail assembly 600 and the lower rail assembly 700 is then completed in an identical manner. More specifically, the inner rail 602 and the outer rail 604 are approximated along the axes of movement M (FIGS. 12, 31, 32) via the application of vertical force(s) thereto which deflects the retention members 610 (FIGS. 18, 20) laterally inward and / or the deflectors 634 (FIGS. 18, 21) laterally outward via engagement (contact) between the outer bearing surfaces 624 and the bearing surfaces 648. Deflection of the retention members 610 causes corresponding deflection of the retention members 660 (FIGS. 18, 22) via engagement (contact) between the inner bearing surfaces 618 and the bearing surfaces 670. More specifically, the retention members 660 are deflected laterally inward, which compresses the insert 606 and forces the bellies 666 into engagement (contact) with the balusters 400, thereby clamping and securing the balusters 400 within the lower rail assembly 700 and upper rail assembly 600.

[0125] Approximation of the inner rail 602 and the outer rail 604 continues until the shoulders 616 (FIGS. 18, 20) on the inner rail 602 are positioned within the recesses 642 defined by the base walls 632 of the outer rail 604, and the locking surfaces 622 (FIGS. 18, 20) on the retention members 610 engage (contact) the locking surfaces 652 (FIGS. 18, 21) on the deflectors 634. Engagement of the locking surfaces 622, 652 locks the inner rail 602 and the outer rail 604 together with the insert 606 positioned (located) laterally between the inner rail 602 (e.g., the retention members 610) and the balusters 400, thereby inhibiting (e.g., preventing) unintended separation of the inner rail 602 and the outer rail 604 and completing assembly of the upper rail assembly 600 and the lower rail assembly 700.

[0126] In certain embodiments, it is envisioned that the retention members 610 and the deflectors 634 may be configured to provide tactile and / or audible indications of proper connection of the inner rail 602 and the outer rail 604 (e.g., upon engagement (contact) of the locking surfaces 622, 652) and, thus, proper assembly of the upper rail assembly 600 and the lower rail assembly 700.

[0127] In one aspect of the present disclosure, a rail assembly is disclosed that includes an inner rail and an outer rail that is configured for connection to the inner rail. The inner rail includes retention members, which are integrally formed therewith, and the outer rail includes deflectors, which are configured for engagement with the retention members upon connection of the outer rail and the inner rail to thereby deflect the retention members into engagement with balusters inserted into the rail assembly and secure the balusters in place.

[0128] In certain embodiments, the inner rail may be unitary in construction.

[0129] In certain embodiments, the inner rail may be exclusively formed from a metallic material.

[0130] In certain embodiments, the retention members and the deflectors may extend in generally orthogonal relation to a longitudinal axis of the rail assembly.

[0131] In certain embodiments, the deflectors may be configured to displace the retention members laterally inward upon connection of the outer rail and the inner rail.

[0132] In certain embodiments, the retention members may be biased laterally outward.

[0133] In certain embodiments, the deflectors may include bearing surfaces that are configured for engagement with the retention members.

[0134] In certain embodiments, the bearing surfaces may be beveled to facilitate connection of the outer rail and the inner rail and engagement of the deflectors with the retention members.

[0135] In certain embodiments, the outer rail may include a crossbeam defining a recess that is configured to receive the balusters.

[0136] In certain embodiments, the deflectors may extend from the crossbeam.

[0137] In another aspect of the present disclosure, a rail assembly is disclosed that includes an outer rail and an inner rail that is configured for connection to the outer rail. The inner rail includes retention members that are configured for inward deflection upon connection of the outer rail and the inner rail to thereby engage and secure balusters within the rail assembly.

[0138] In certain embodiments, the retention members may be integrally formed with the inner rail.

[0139] In certain embodiments, the inner rail may be formed from a single piece of material.

[0140] In certain embodiments, the inner rail may be exclusively formed from metallic material.

[0141] In certain embodiments, the outer rail may include deflectors that are configured for engagement with the retention members upon connection of the inner rail and the outer rail to thereby reposition the retention members from a normal position into a deflected position.

[0142] In certain embodiments, the outer rail may include a crossbeam defining a recess that is configured to receive the balusters.

[0143] In certain embodiments, the deflectors may extend from the crossbeam.

[0144] In another aspect of the present disclosure, a rail assembly is disclosed that includes an outer rail and an inner rail that is configured for connection to the outer rail such that, upon connection of the outer rail and the inner rail, balusters are automatically secured within the rail assembly, wherein the inner rail is unitary in construction.

[0145] In certain embodiments, the inner rail may be formed from a single piece of metallic material.

[0146] In certain embodiments, the inner rail may include retention members that are configured for inward deflection upon connection of the inner rail and the outer rail to thereby secure the balusters within the rail assembly.

[0147] In certain embodiments, the outer rail may include a base wall and a channel that extends into the base wall.

[0148] In certain embodiments, the channel may extend towards the inner rail.

[0149] In certain embodiments, the rail assembly may further include a support member that is configured for insertion into the channel.

[0150] In certain embodiments, the channel may define shoulders that extend laterally inward and which are configured to interface with the support member.

[0151] In certain embodiments, the support member may define slots that are configured to receive the shoulders.

[0152] In certain embodiments, the support member may include an upper end with a generally T-shaped configuration.

[0153] In certain embodiments, the channel may define an upper wall that includes a notch.

[0154] In certain embodiments, the notch may extend towards the inner rail.

[0155] In certain embodiments, the notch may be configured to receive an electrical component.

[0156] In certain embodiments, the notch may be configured to receive LED lighting.

[0157] In another aspect of the present disclosure, a rail assembly is disclosed that is configured to receive balusters. The rail assembly includes: an inner rail; an outer rail that is configured for connection to the inner rail; and an insert that is positioned within the outer rail and which is configured for engagement with the balusters. The insert includes: a backspan; retention members that extend from the backspan; and a foot that extends from the backspan.

[0158] In certain embodiments, the retention members and the foot may extend from the backspan in generally opposite directions.

[0159] In certain embodiments, the retention members may include: first segments, which are connected to the backspan; second segments, which extend from the first segments and are arcuate in configuration; and third segments, which extend from the second segments.

[0160] In certain embodiments, the second segments may include a curvature that extends laterally inward.

[0161] In certain embodiments, the third segments may extend laterally inward from the second segments.

[0162] In another aspect of the present disclosure, a rail assembly is disclosed that is configured to receive balusters. The rail assembly includes: an inner rail; an outer rail that is configured for connection to the inner rail; and an insert that is positioned within and which is directly supported by the outer rail such that, upon assembly of the rail assembly and insertion of the balusters, the insert is positioned laterally between the inner rail and the balusters.

[0163] In certain embodiments, the inner rail may include first retention members.

[0164] In certain embodiments, the insert may include second retention members that are configured for engagement with the first retention members.

[0165] In certain embodiments, the first retention members may be formed integrally with the inner rail.

[0166] In certain embodiments, the second retention members may be formed integrally with the insert.

[0167] In certain embodiments, the outer rail may include deflectors that are configured for engagement with the first retention members such that, upon connection of the outer rail and the inner rail, the deflectors deflect the first retention members into engagement with the second retention members and thereby deflect the second retention members into engagement with the balusters.

[0168] In certain embodiments, the insert may further include a backspan, which connects the second retention members such that the second retention members extend from the backspan in a first direction, and a foot, which extends from the backspan in a second direction that is generally opposite to the first direction.

[0169] In certain embodiments, the foot may include a generally T-shaped cross-sectional configuration.

[0170] In certain embodiments, the outer rail may include: an outer wall; sidewalls that extend from the outer wall; and a crossbeam that extends between the sidewalls.

[0171] In certain embodiments, the crossbeam may include a channel that is configured to receive the insert.

[0172] In certain embodiments, the foot may extend into the channel.

[0173] In another aspect of the present disclosure, a rail assembly is disclosed that is configured to receive balusters. The rail assembly includes: an inner rail; an outer rail that is configured for connection to the inner rail; and an insert that is positioned within the outer rail. The insert is configured to receive the balusters such that that balusters extend inwardly into the insert.

[0174] In certain embodiments, the insert may include a body and a foot that extends from the body.

[0175] In certain embodiments, the foot may be configured for insertion into the outer rail.

[0176] In certain embodiments, the body may include a generally U-shaped cross-sectional configuration defining a chamber that is configured to receive the balusters.

[0177] In certain embodiments, the body may include a backspan and retention members that extend from the backspan.

[0178] In certain embodiments, the retention members and the foot may extend from the backspan in generally opposite directions.

[0179] In certain embodiments, the retention members may include: first segments, which are connected to the backspan; second segments, which extend from the first segments; and third segments, which extend from the second segments.

[0180] In certain embodiments, the second segments may be arcuate in configuration.

[0181] In certain embodiments, the second segments may include a curvature that extends laterally inward.

[0182] In certain embodiments, the third segments may extend laterally inward from the second segments.

[0183] In another aspect of the present disclosure, a method of assembling a rail assembly is disclosed. The method includes: slidably inserting an insert into a channel of an outer rail; approximating the outer rail and an inner rail; and deflecting the inner rail to compress the insert into balusters extending through the inner rail.

[0184] In certain embodiments, the method may further include positioning the insert laterally between the inner rail and the balusters.

[0185] In certain embodiments, the method may further include locking the rail assembly together via engagement of locking surfaces on the inner rail and the outer rail.

[0186] 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.

[0187] 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.

[0188] 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.

[0189] 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).

[0190] 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.

[0191] 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.

[0192] 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.

Claims

1. A rail assembly configured to receive balusters, the rail assembly comprising:an inner rail;an outer rail configured for connection to the inner rail; andan insert positioned within and directly supported by the outer rail such that, upon assembly of the rail assembly and insertion of the balusters, the insert is positioned laterally between the inner rail and the balusters.

2. The rail assembly of claim 1, wherein the inner rail includes first retention members, and the insert includes second retention members configured for engagement with the first retention members.

3. The rail assembly of claim 2, wherein the first retention members are formed integrally with the inner rail.

4. The rail assembly of claim 2, wherein the second retention members are formed integrally with the insert.

5. The rail assembly of claim 2, wherein the outer rail includes deflectors configured for engagement with the first retention members such that, upon connection of the outer rail and the inner rail, the deflectors deflect the first retention members into engagement with the second retention members and thereby deflect the second retention members into engagement with the balusters.

6. The rail assembly of claim 2, wherein the insert further includes:a backspan connecting the second retention members such that the second retention members extend from the backspan in a first direction; anda foot extending from the backspan in a second direction generally opposite to the first direction.

7. The rail assembly of claim 6, wherein the foot includes a generally T-shaped cross-sectional configuration.

8. The rail assembly of claim 6, wherein the outer rail includes:an outer wall;sidewalls extending from the outer wall; anda crossbeam extending between the sidewalls.

9. The rail assembly of claim 8, wherein the crossbeam includes a channel configured to receive the insert.

10. The rail assembly of claim 9, wherein the foot extends into the channel.

11. A rail assembly configured to receive balusters, the rail assembly comprising:an inner rail;an outer rail configured for connection to the inner rail; andan insert positioned within the outer rail, wherein the insert is configured to receive the balusters such that that balusters extend inwardly into the insert.

12. The rail assembly of claim 11, wherein the insert includes:a body; anda foot extending from the body, wherein the foot is configured for insertion into the outer rail.

13. The rail assembly of claim 12, wherein the body includes a generally U-shaped cross-sectional configuration defining a chamber configured to receive the balusters.

14. The rail assembly of claim 12, wherein the body includes:a backspan; andretention members extending from the backspan, wherein the retention members and the foot extend from the backspan in generally opposite directions.

15. The rail assembly of claim 14, wherein the retention members include:first segments connected to the backspan;second segments extending from the first segments, wherein the second segments are arcuate in configuration; andthird segments extending from the second segments.

16. The rail assembly of claim 15, wherein the second segments include a curvature extending laterally inward.

17. The rail assembly of claim 16, wherein the third segments extend laterally inward from the second segments.

18. A method of assembling a rail assembly, the method comprising:slidably inserting an insert into a channel of an outer rail;approximating the outer rail and an inner rail; anddeflecting the inner rail to compress the insert into balusters extending through the inner rail.

19. The method of claim 18, further including:positioning the insert laterally between the inner rail and the balusters.

20. The method of claim 18, further including:locking the rail assembly together via engagement of locking surfaces on the inner rail and the outer rail.

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