Railing system and method of installation thereof

Abstract

A railing system which includes a post, a rail member, and a bracket assembly for coupling the rail member to the post. The bracket assembly may include a support bracket that is coupled to the post and that supports an end portion of the rail member, at least one fastener assembly for coupling the support bracket to the rail member, and a cover member. The at least one fastener assembly may include a fastener component and a washer component, such that the fastener component secures the washer component to an outer surface of the support bracket. The cover member may include a locking element that engages the washer component to lock the cover member in an installed position wherein the cover member covers the fasteners.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 63 / 757,938, filed Feb. 13, 2025, the entirety of which is incorporated herein by reference.BACKGROUND

[0002] Decks, porches, balconies, and the like are architectural structures that are typically elevated above the surrounding ground level to extend living space to the outdoors and / or provide users with a space on which to relax, eat, and perform other activities. Typically, a railing system is positioned around the perimeter of such elevated structures to prevent injuries that could occur from a fall. Railing systems are often assembled with hardware and fasteners, which can provide an unsightly aesthetic. A need exists for a railing system and / or a retrofit for a railing system that provides a clean and desirable outward aesthetic to a user, while being simple to assemble and install.SUMMARY

[0003] The invention may be directed to a railing system which includes a post, a rail member, and a bracket assembly for coupling the rail member to the post. The bracket assembly may include a support bracket that is coupled to the post and that supports an end portion of the rail member, at least one fastener assembly for coupling the support bracket to the rail member, and a cover member. The at least one fastener assembly may include a fastener component and a washer component, such that the fastener component secures the washer component to an outer surface of the support bracket. The cover member may include a locking element that engages the washer component to lock the cover member in an installed position wherein the cover member covers the fasteners.

[0004] In another aspect, the invention may be a railing system comprising: a post; a rail member; and a bracket assembly configured to couple the rail member to the post, the bracket assembly comprising: a support bracket configured to be attached to the post with one or more attachment fasteners, the support bracket configured to support an end portion of the rail member; at least one fastener assembly comprising a fastener component and a washer component, the fastener component configured to secure the washer component to an outer surface of the support bracket; and a cover member comprising an inner surface and at least one locking element protruding from the inner surface, the cover member configured to be placed into an installed position wherein the cover member covers the one or more attachment fasteners and the at least one fastener assembly, the at least one locking element of the cover member configured to engage the washer component of the fastener assembly to lock the cover member in the installed position.

[0005] In yet another aspect, the invention may be a railing system comprising: a post; a rail member; and a bracket assembly configured to couple the rail member to the post, the bracket assembly comprising: a support bracket configured to be attached to the post with one or more attachment fasteners, the support bracket configured to support an end portion of the rail member; at least one fastener assembly comprising a fastener component and a washer component, the fastener component configured to secure the washer component to an outer surface of the support bracket; and a cover member comprising an inner surface and at least one pair of track elements protruding from the inner surface that collectively define a track channel, the cover member configured to be placed into an installed position wherein the cover member covers the one or more attachment fasteners and the at least one fastener assembly and the washer nests within the track channel.

[0006] In still another aspect, the invention may be a method of installing a railing system, the method comprising: supporting an end portion of a rail member with a support bracket; attaching the support bracket to a post with one or more attachment fasteners; securing a washer component to an outer surface of the support bracket; and sliding a cover member along the rail member towards the support bracket until the cover member is in an installed position wherein the cover member covers and at least partially encloses the support bracket, the cover member comprising a locking protuberance that engages the washer component to lock the cover member in the installed position.

[0007] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The features of the exemplary embodiments of the present invention will be described with reference to the following drawings, where like elements are labeled similarly, and in which:

[0009] FIG. 1 is a perspective view of a deck with a railing system located along a perimeter thereof;

[0010] FIG. 2 is a close-up perspective view of a portion of the railing system of FIG. 1;

[0011] FIG. 3 is an exploded view of the portion of the railing system shown in FIG. 2;

[0012] FIG. 4 is an exploded view of a bracket assembly of the railing system of FIG. 1;

[0013] FIG. 5A is a top perspective view of a cover member of the bracket assembly of FIG. 4;

[0014] FIG. 5B is a bottom perspective view of the cover member of FIG. 5A;

[0015] FIG. 6A is a front perspective view of a washer component of a fastener assembly of the bracket assembly of FIG. 4;

[0016] FIG. 6B is a rear perspective view of the washer component of FIG. 6A;

[0017] FIGS. 7A-7C illustrate the process of attaching a support bracket to the post with attachment fasteners, attaching the support bracket to the rail member with the fastener assembly, and attaching a top cover to the rail member;

[0018] FIG. 8 illustrates the process of positioning the cover member around the rail member;

[0019] FIG. 9 is a cross-sectional view taken along line IX-IX of FIG. 8;

[0020] FIG. 10 illustrates the process of sliding the cover member along the rail member to at least partially cover the support bracket;

[0021] FIG. 11A is a cross-sectional view taken along line XI-XI of FIG. 10, prior to a locking element of the cover member engaging the washer component;

[0022] FIG. 11B is a cross-sectional view taken along line XI-XI of FIG. 10, illustrating the locking element of the cover member engaging the washer component; and

[0023] FIG. 12 is a cross-sectional view taken along line XII-XII of FIG. 10.DETAILED DESCRIPTION

[0024] The features and benefits of the invention are illustrated and described herein by reference to exemplary embodiments. This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. Accordingly, the disclosure expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features.

[0025] In the description of embodiments disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,”“upper,”“horizontal,”“vertical,”, “above,”“below,”“up,”“down,”“top” and “bottom” as well as derivative thereof (e.g., “horizontally,”“downwardly,”“upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “attached,”“affixed,”“connected,”“coupled,”“interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

[0026] As used throughout, any ranges disclosed herein are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range.

[0027] Referring first to FIG. 1, a deck 10 is illustrated with a railing system 20 positioned along the perimeter of the deck 10. While the railing system 20 is illustrated on a deck 10, the railing system 20 as described herein may be used with other elevated architectural structures, such as porches, balconies, rooftops, or the like. The exact location of the railing system 20 on the deck 10 or other architectural structure is not to be limiting of the invention as described herein. The exact manner in which the railing system 20 is attached to the deck 10 or other architectural structure is not to be limiting of the invention as described herein.

[0028] In the exemplified embodiment, the railing system 20 comprises a plurality of posts 300 that extend vertically upward from the top surface of the deck 10. The posts 300 may be coupled directly or indirectly to the top surface of the deck 10. Alternatively, the posts 300 may be coupled to an outer surface of the deck 10 or to a fascia located along an outer surface of the deck 10. The railing system 20 further comprises a plurality of rail members 400 that extend between each pair of adjacent ones of the posts 300. The rail members 400 may be coupled to the posts with bracket assemblies, the details of which will be provided below. The rail members 400 are depicted coupled to the posts 300 proximal to the top ends of the posts 300. An additional rail member may extend between each pair of adjacent ones of the posts 300 proximal to the lower ends of the posts 300 (and near the deck surface). The rail members 400 (and any additional rail members which are not shown) may be coupled to each of the posts 300 with a bracket assembly 30, which will be described in greater detail below.

[0029] Although not shown, the railing system 20 may further comprise an infill assembly. The infill assembly may comprise panels, pickets, balusters, cables, or the like. For example, the infill assembly may comprise glass panels, such that one of the glass panels is positioned below the rail member 400 and between each pair of adjacent ones of the posts 300. Alternatively, the infill assembly may comprise pickets or balusters that extend vertically between the deck 10 or a lower rail member and the depicted rail member 400. In yet another embodiment, the infill assembly may comprise cables which may extend horizontally between the adjacent posts 300. Thus, the infill assembly may take on different structural forms depending on user preference, zoning requirements, safety considerations, or the like.

[0030] Referring to FIGS. 2 and 3, the railing system 20 will be further described. FIGS. 2 and 3 illustrate a portion of the railing system 20 which includes a portion of one of the posts 300, a portion of one of the rail members 400, and the bracket assembly 30 which is used to facilitate the attachment of the rail member 400 to the post 300.

[0031] The post 300 may include a post body 301 and a post cap 302 that is coupled to or placed atop of the top end of the post body 301. The post body 301 is hollow in the exemplified embodiment, but may be solid in alternative embodiments. The post body 301 and the post cap 302 may be formed from a plastic material such as a composite plastic material, polyvinyl chloride, or the like. Alternative materials could be used, such as metal, wood, or the like. The post cap 302 may be coupled to the post body 301 with fasteners or via a mechanical engagement such as friction fit, nub / recess, or the like. In an alternative embodiment, the post cap 302 may be omitted.

[0032] The rail member 400 may comprise a first end 401 and a second end 402, with the rail member 400 being elongated along a longitudinal axis A-A in a direction between the first and second ends 401, 402. The rail member 400 may be formed from the same material as the post 300, specifically a plastic material such as a composite plastic material, polyvinyl chloride, or the like. Alternative materials could be used, such as metal, wood, or the like. The rail member 400 may be a T-rail, meaning that the rail member 400 has a T-shaped cross-sectional profile. In that regard, the rail member 400 may comprise a lower portion 403 and an upper portion 406. The lower portion 403 may have a first side outer surface 404 and a second side outer surface 405. The upper portion 406 may have a central portion that is located above and in alignment with the lower portion 403, a first side portion 407 that protrudes beyond the first side outer surface 404 of the lower portion 403, and a second side portion 408 that protrudes beyond the second side outer surface 405 of the lower portion 403. The first side portion 407 may have a first downwardly facing shoulder 409 that extends generally perpendicularly from the first side outer surface 404 of the lower portion 403. The second side portion 408 may have a second downwardly facing shoulder 410 that extends generally perpendicularly from the second side outer surface 405 of the lower portion 403. Each of the lower and upper portions 403, 406 of the rail member 400 may be hollow. A divider wall 411 may separate the hollow interior of the lower portion 403 from the hollow interior of the upper portion 406.

[0033] In alternative embodiments, the rail member may have other cross-sectional profiles, such as being square-shaped, rectangular-shaped, I-shaped, irregularly shaped, or the like. The inventive concepts described herein may be applied to rail members having a variety of different shapes, and as such the specific shape of the rail member 400 is not to be limiting of the invention in all embodiments.

[0034] The bracket assembly 30 may comprise a set of distinct components and parts that work together to attach the rail member 400 to the post 300. The bracket assembly 30 may comprise a support bracket 110, one or more attachment fasteners 160 for attaching the support bracket 110 to the post 300 and / or the rail member 400, a top cover 180, at least one fastener assembly 200, and a cover member 250 that is configured to attach to the at least one fastener assembly 200 while covering and / or enclosing the at least one fastener assembly 200 and the one or more attachment fasteners 160 from view of an observer. The at least one fastener assembly 200 may comprise a fastener component 210 and a washer component 230.

[0035] Referring to FIG. 4, the components of the bracket assembly 30 are again illustrated in a larger format to facilitate a more detailed description of the components. The support bracket 110 comprises a bottom wall portion 111, a first side wall portion 112, and a second side wall portion 113 that collectively form a U-shape. The support bracket 110 comprises a receiving cavity 115 that is configured to receive an end portion of the rail member 400. Specifically, an end portion of the rail member 400 is configured to be placed within the receiving cavity 115 of the support bracket 110 while resting atop of the bottom wall portion 111 of the support bracket 110. The first and second side wall portions 112, 113 of the support bracket 110 are configured to extend alongside of the first side outer surface 404 and the second side outer surface 405 of the lower portion 403 of the rail member 400, respectively, when the rail member 400 is positioned within the receiving cavity 115 of the support bracket 110.

[0036] The support bracket 110 may comprise a plurality of different apertures therethrough for receiving the fasteners described herein to facilitate the attachment of the support bracket 110 to the post 300 and to the rail member 400. Specifically, the first side wall portion 112 may comprise an aperture 116 and the second side wall portion 113 may comprise an aperture 117. The apertures 116, 117 may be configured to receive the fastener components 210 of the fastener assemblies 200 to facilitate the attachment of the support bracket 110 to the rail member 400. Each of the fastener components 210 may have a head portion 211 and a shank portion 212. The shank portions 212 may be threaded, or at least threaded along at least a portion of their length. The fastener components 210 may extend through the washer components 230 and then through the apertures 116, 117 to secure the washer components 230 to the exterior of the support bracket 110. The washer components 230 will be described in more detail below with reference to FIGS. 6A and 6B.

[0037] The support bracket 110 may comprise a first flange extension 118 protruding from the outer surface of the first side wall portion 112. The first flange extension 118 may comprise an upper wall portion 119 having an aperture 120 and a rear wall portion 121 having an aperture 122. The aperture 120 in the upper wall portion 119 may be configured to receive one of the attachment fasteners 160a, which may then extend into the first side portion 407 of the upper portion 406 of the rail member 400. The aperture 122 in the rear wall portion 121 may be configured to receive one of the attachment fasteners 160b, which may then extend into the post 300.

[0038] The support bracket 110 may comprise a second flange extension 123 protruding from the outer surface of the second side wall portion 113. The second flange extension 123 may comprise an upper wall portion 124 having an aperture 125 and a rear wall portion (not visible, but identical to the same feature of the first flange extension 118) having an aperture. The aperture 125 in the upper wall portion 124 may be configured to receive one of the attachment fasteners 160c, which may then extend into the second side portion 408 of the upper portion 406 of the rail member 400. The aperture in the rear wall portion (not visible as noted above) may be configured to receive one of the attachment fasteners 160d, which may then extend into the post 300. Thus, the various attachment fasteners 160a-d and the fastener components 210 of the fastener assemblies 200 may facilitate the attachment of the support bracket 110 to both the post 300 and the rail member 400.

[0039] The top cover 180 may comprise a rear wall 181 and an outer wall 182 that protrudes from an edge of the rear wall 181 along three sides of the rear wall 181. The outer wall 182 may have a U-shaped configuration with a top portion 183, a first side portion 184, and a second side portion 185. Distal ends 186, 187 of the first and second side portions 184, 185 of the outer wall 182 may be curled or curved inwardly. This enables the top cover 180 to be snap-fit connected to the upper portion 406 of the rail member 400. Alternatively, the top cover 180 may be slid over an end of the upper portion 406 of the rail member 400. In either case, the curled or curved distal ends 186, 187 of the side portions of the outer wall 182 may be configured to engage with the downwardly facing shoulders 409, 410 of the upper portion 406 of the rail member 400 to facilitate the attachment of the top cover 180 to the rail member 400. In an embodiment, no fasteners (i.e., screws, bolts, nails, etc.) are needed to attach the top cover 180 to the upper portion 406 of the rail member 400. In some embodiments, the top cover 180 may be omitted or not used, depending on the desired aesthetic for the end user. The top cover 180 may not perform any supporting function for supporting the rail member 400, but when used creates a uniform aesthetic with the support bracket 110 and / or the cover member 250.

[0040] Referring now to FIGS. 4, 5A and 5B concurrently, the cover member 250 will be described. The cover member 250 comprises a bottom wall 251, a first side wall 252 extending from the bottom wall 251, and a second side wall 253 extending from the bottom wall 251. The bottom wall 251 and the first and second side walls 252, 253 collectively form a U-shape, such that the cover member 250 is a U-shaped component in the exemplified embodiment. The shape of the cover member 250 may correspond with and be similar or the same as the shape of the support bracket 110 so that the cover member 250 may cover the support bracket 110 when installed as described herein below. The cover member 250 further comprises a front side 254, a rear side 255, an outer surface 256, and an inner surface 257.

[0041] The cover member 250 may comprise a first locking element 260 located on the inner surface 257 of the first side wall 252 and a second locking element (not visible) located on the inner surface 257 of the second side wall 253. While the second locking element is not visible, it is hereby noted that the second locking element is identical to the first locking element 260 in terms of its positioning on the second side wall 253 and its structure. Thus, the description of the first locking element 260 is entirely8 applicable to the second locking element except that the second locking element is located on the inner surface 257 of the second side wall 253 and the first locking element 260 is located on the inner surface 257 of the first side wall 252.

[0042] The first locking element 260 may be positioned closer to the rear side 255 of the cover member 250 than to the front side 254 of the cover member 250. The first locking element 260 may be a protrusion that protrudes from the inner surface 257 of the cover member 250. The first locking element 260 may comprise a ramped upper surface 261 and a vertical and flat rear locking surface 262. The rear locking surface 262 may extend generally vertically downward from an end of the ramped upper surface 261 to the inner surface 257, to facilitate the locking of the first locking element 260 to the washer component 230 of the fastener assembly 200, as described further below.

[0043] The cover member 250 further comprises a first pair of track elements 270 protruding from the inner surface 257 of the cover member 250 along the first side wall 252 and a second pair of track elements 290 protruding from the inner surface 257 of the cover member 250 along the second side wall 253. The second pair of track elements 290 are identical to the first pair of track elements 270, except that the second pair of track elements 290 are located on the second side wall 253. Thus, the description of the first pair of track elements 270 below is entirely applicable to the second pair of track elements 290 except that the second pair of track elements 290 are on the second side wall 253 instead of the first side wall 252.

[0044] The first pair of track elements 270 comprises a first track element 271 and a second track element 272, each of which protrudes form the inner surface 257 of the cover member 250 along the first side wall 252. The first track element 271 comprises a first wall 273 that protrudes from the inner surface 257 of the first side wall 252 in a direction towards the second wall 253 and a second wall 274 that extends from a distal end of the first wall 273 in a direction towards the second track element 272. A channel 277 is formed between the second wall 274 of the first track element 271 and the inner surface 257 of the first side wall 252. The second track element 272 comprises a first wall 275 that protrudes from the inner surface 257 of the first side wall 252 in a direction towards the second side wall 253 and a second wall 276 that extends from a distal end of the first wall 275 in a direction towards the first track element 271. A channel 278 is formed between the second wall 276 of the second track element 272 and the inner surface 257 of the first side wall 252. The first track element 271 is generally L-shaped, formed by the first and second walls 273, 274. The second track element 272 is generally L-shaped, formed by the first and second walls 275, 276.

[0045] The first and second track elements 271, 272 define a track channel 279 therebetween. Specifically, the space between the first and second track elements 271, 272 forms a track channel 279 that is configured to receive the washer component 230 of the fastener assembly 200. In the exemplified embodiment, the locking element 260 is located within the track channel 279. The locking element 260, however, may not be centrally located within the track channel 279, but may be located closer to a rear portion of the track channel 279 near the rear side 255 of the cover member 250. When the cover member 250 is in its installed position, the washer component 230 of the fastener assembly 200 may be located within the track channel 279 and the locking element 260 may be in locking engagement with the washer component 230, as described in more detail below.

[0046] Referring to FIGS. 6A and 6B, the washer component 230 of the fastener assembly 200 will be described. As noted and shown in FIG. 4, for example, there may be two of the fastener assemblies 200 and therefore two of the washer components 230. However, a single fastener assembly 200 and / or a single washer component 230 may be sufficient in alternative embodiments. The washer component 230 comprises a front surface 231 and a rear surface 232 opposite the front surface 231. The washer component 230 further comprises a washer cavity 233 in the front surface 231. The washer cavity 233 is defined by an inner surface 234 of the washer component 230 and a floor 235. The washer cavity 233 extends from the floor 2135 to an opening 240 in the front surface 231. The washer cavity 233 may extend from the front surface 231 of the washer component 230 to the floor 235. The floor 235 comprises an aperture or through-hole 236 that extends from a top / upper surface of the floor 235 to the rear surface 232 of the washer component 230. The aperture 236 is sized and configured to allow the shank portion 212 of the fastener component 210 to pass therethrough while preventing the head portion 211 of the fastener component 210 from passing therethrough. Thus, when the washer component 230 is coupled to the support bracket 110 with the fastener component 210, the shank portion 212 of the fastener component 210 extends through the aperture 236 of the washer component 230 and into the support bracket 110 and the head portion 211 of the fastener component 210 remains within the washer cavity 233.

[0047] The washer component 230 comprises an outer surface 237. Furthermore, the washer component 230 comprises a flange 238 that protrudes from the outer surface 237 at a location proximate the front surface 231. In the exemplified embodiment, the flange 238 is an annular flange that extends continuously around the full circumference of the washer component 230. In other embodiments, the flange 238 may comprise distinct flange segments that are spaced apart and which collectively form the flange 238. The flange 238 is configured to form an engagement with the first pair of track elements 270 to facilitate the attachment of the cover member 250 to the fastener assembly 200, which will be described in greater detail below. The flange 238 may comprise a top surface 241 and a bottom surface 242. The top surface 241 may be angled downwardly as it extends further from the outer surface 237 of the washer component 230. The bottom surface 242 of the flange 238 may be oriented perpendicularly relative to the outer surface 237.

[0048] It should be appreciated that the washer component 230 is not simply a flat plate as with traditional washers. A traditional washer may comprise the floor 235 and the aperture 236. However, the washer component 230 additional comprises a sidewall 239 that extends from the floor 235 to the front surface 231 such that the sidewall 239 and the floor 235 define the washer cavity 233.

[0049] Referring to FIGS. 7A and 7B, the attachment of the support bracket 110 and the top cover 180 to the rail member 400 and the attachment of the support bracket 110 to the post 300 will be described. Although a specific sequence is described herein, it should be noted that the components may be positioned and attached together in other sequences on other embodiments. First, the support bracket 110 is positioned at a desired position / elevation along the post 300. Next, the attachment fasteners 160b, 160d are inserted through the apertures 122 and into the post 300 to attach / affix the support bracket 110 to the post 300. A drill, a screwdriver, or other tool may be used for this purpose.

[0050] Next, the end portion of the rail member400 is positioned in the receiving cavity 115 of the support bracket 110 so that the bottom of the rail member 400 rests atop of the bottom wall portion 111 of the support bracket 110. Since the support bracket 110 is already attached to the post 300 at this juncture, the support bracket 110 is capable of supporting the rail member 400. More specifically, there would generally be two support brackets 110 attached to two adjacent posts 300 at this point. Then, a first end portion of the rail member 400 is placed within the receiving cavity 115 of a first one of the support brackets 110 and a second end portion of the rail member 400 is placed within the receiving cavity of a second one of the support brackets 110. The two support brackets 110 attached to the two adjacent posts 300 collectively support the rail member 400 in the desired orientation (horizontal, or possibly at an angle if the rail is located along a stairway).

[0051] Next, the attachment fasteners 160a, 160c are inserted into the apertures 120, 125 of the support bracket 110 and into the rail member 400 to form a fixed attachment between the support bracket 110 and the rail member 400. The attachment fastener 160a may extend through the aperture 120 of the support bracket 110 and into the first side portion 407 of the upper portion 406 of the rail member 400 and the attachment fastener 160c may extend through the aperture 125 of the support bracket 110 and into the second side portion 408 of the upper portion 406 of the rail member 400. At this point, the support bracket 100 is attached to the post 300 and to the rail member 400. Thus, the rail member 400 is fixed in position within the receiving cavity 115 of the support bracket 110 and cannot be removed therefrom without first removing the attachment fasteners 160a, 160c.

[0052] At any time, the top cover 180 may also be attached to the rail member 400. As noted previously the top cover 180 may be attached to the rail member 400 via a snap-fit attachment, without the need for any tools or hardware. The top cover 180 may be moved downwardly towards the top end of the rail member 400 from above until the curved distal ends 186, 187 of the outer wall 182 engage the downwardly facing shoulders 409, 410 of the first and second side portions 407, 408 of the upper portion 406 of the rail member 400. The top cover 180 may be attached to the rail member 400 prior to placing the rail member 400 into the receiving cavity 115 of the support bracket 110 or after placing the rail member 400 into the receiving cavity 115 of the support bracket 110.

[0053] In one specific embodiment, the initial installation sequence may be as follows. First, the support bracket 110 may be aligned with an end of the rail member 400. Next, the support bracket 110 may be attached to the rail member 400 with the attachment fasteners 160a, 160c. Next, the top cover 180 may be slid over the end of the rail member 400. It is noted that FIG. 7A illustrates a downward arrow indicating that the top cover 180 is pressed downwardly onto the rail member 400. However, the top cover 180 may be slid onto the end of the rail member 400 as noted herein instead. Next, the assembly which includes the support bracket 110, the rail member 400, and the top cover 180 may be attached to the post 300 with the attachment fasteners 160b, 160d. In an embodiment, this may be a preferred installation sequence, although as noted, variations to the installation sequence may be possible in accordance with the invention described herein.

[0054] With reference to FIG. 7C, after the support bracket 110 is attached to the rail member 400 and to the post 300 and the top cover 180 is slid onto the end of the rail member 400, the fastener assemblies 200 may be attached to the assembly. It should be noted that the fastener assemblies 200 may be used to attach the support bracket 110 to the rail member 400 prior to using the attachment fasteners 160a, 160c for that purpose. Thus, once again, it is noted that the steps described herein for the installation and assembly of the railing system 20 may occur in a sequence that differs from the specific sequence recited herein.

[0055] As noted, each of the fastener assemblies 200 comprises the fastener component 210 and the washer component 230. In the exemplified embodiment, there are two of the fastener assemblies 200, one for use along the first side wall portion 112 of the support bracket 110 and one for use along the second side wall portion 113 of the support bracket 110. In an alternative embodiment, there may be only one of the fastener assemblies 200 instead of two. First, the shank portion 212 of the fastener component 210 is inserted into and through the aperture 236 of the washer component 230 via the front surface 231 of the washer component 230. That is, the shank portion 212 of the fastener component 210 is inserted into the washer cavity 233 and then into and through the aperture 236 so that the washer component 230 is positioned around the outside of the shank portion 212 of the fastener component 210. Next, the shank portion 212 of the fastener component 210 is inserted through the aperture 116 (or 117) in the first side wall 112 (or the second side wall 113) of the support bracket 110 and into the rail member 400. This provides an additional attachment of the support bracket 110 to the rail member 400 via the fastener component 210. Furthermore, this secure the washer component 230 to the outer surface of the support bracket 210. If there are two of the fastener assemblies 200, one of the washer components 230 is secured to the outer surface of the first side wall 112 of the support bracket 110 and the other one of the washer components 230 is secured to the outer surface of the second side wall 113 of the support bracket 110.

[0056] Referring to FIGS. 8 and 9, the next step in the installation process is to attach the cover member 250 to the fastener assemblies 200. Thus, FIGS. 8 and 9 illustrate the cover member 250 positioned around the lower portion 403 of the rail member 400 in a location that is spaced from the support bracket 110. As best shown in FIG. 9, the head portion 211 of the fastener component 210 is located within the washer cavity 233 of the washer component 230 while the shank portion 212 of the fastener component 210 passes through the aperture 116, 117 and into the rail member 400. As noted above, the washer component 230 is secured to the outer surface of the support bracket 110. As shown with the arrows in FIGS. 8 and 9, once the cover member 250 is placed around the lower portion 403 of the rail member 400, the cover member 250 is slid along the lower portion 403 of the rail member 400 towards the support bracket 110.

[0057] FIG. 10 illustrates the cover member 250 after it has been slid over the support bracket 110 such that the cover member 250 covers all of the attachment fasteners 160 and the fastener assembly 200. In the exemplified embodiment, the cover member 250 fully covers and encloses the entirety of the support bracket 110 so that only the cover member 250 and the top cover 180 are visible (in addition to the rail member 400 and the post 300). This provides for a clean and desirable aesthetic. Thus, when the cover member 250 is in its installed position as shown in FIG. 10, the support bracket 110 may no longer be visible to the end user.

[0058] Next, referring to FIGS. 11A and 11B, the process of altering the cover member 250 into the installed position will be described in greater detail. First, as shown in FIG. 11A, as the cover member 250 is slid along the rail member 400 towards the support bracket 110, the washer component 230 enters the track channel 279 defined by the pair of track elements 270 (and the track channel defined by the pair of track elements 290). The positioning of the washer component 230 relative to the track elements 270 will be described in greater detail below with reference to FIG. 12. As shown in FIG. 11,A, the cover member 250 is moved along the rail member 400 until the locking element 260 of the cover member 250 abuts the flange 238 of the washer component 230. The installer then applies a bit of pressure to the cover member 250 to allow the locking element 260 to pass over the top surface 241 of the flange 238 and over the front surface 231 of the washer component 230. The angled orientation of the top surface 241 of the flange 238 may help guide the locking element 260 therealong. The cover member 250 may flex outwardly during this process.

[0059] As shown in FIG. 11B, the cover member 250 continues to be slid towards the post 300 until the locking element 260 snaps into the washer cavity 233 of the washer component 230. That is, the locking element 260 passes entirely beyond the flange 238 and the front surface 231 of the washer component 230 and passes through the opening 240 and into the washer cavity 233. The rear locking surface 262 of the locking element 260 engages with the inner surface 234 of the washer component 230, which prevents the cover member 250 from sliding back away from the post 300 in the opposite direction. Additional flexing or manipulation of the cover member 250 may be required to facilitate a detachment of the cover member 250 from the washer component 230 of the fastener assembly 200. A user simply pulling the cover member 250 away from the post 300 will not be sufficient to separate the cover member 250 from the washer component 230 of the fastener assembly 200.

[0060] Referring to FIG. 12, the interaction between the first and second track elements 271, 272 of the first pair of track elements 270 and the washer component 230 will be described. It should be appreciated that the interaction between the first and second track elements of the second pair of track elements 290 and the other washer component 230 is the same, and this will not be described separately for brevity. As the cover member 250 is slid towards the post 300 and over the support bracket 110, the washer component 230 passes into the track channel 279 defined between the first and second track elements 271, 272. Furthermore, as the washer component 230 passes into the channel 277, the second walls 274, 276 of the first and second track elements 271, 272 slide within the space between the bottom surface 242 of the flange 238 of the washer component 230 and the outer surface of the support bracket 110. At the same time, the flange 238 of the washer component 230 slides within the channel 277 formed between the second wall 274 of the first track element 271 and the inner surface 257 of the first side wall 252 of the cover member 250 and within the channel 238 formed between the second wall 276 of the second track element 272 and the inner surface 257 of the second side wall 252 of the cover member 250. This engagement between the pairs of track elements 270, 290 and the washer components 230 constrains the cover member 230 in multiple directions. The combination of the engagement between the track elements 270, 290 and the washer components 230 and the engagement between the locking elements 260 and the washer components 230 constrains the cover member 250 in all directions.

[0061] In an embodiment, the cover member 250 may be a retrofit part configured for use with the support bracket 110. For example, the support bracket 110 may be used to support the rail member 400 with the various attachment fasteners 160. Without the cover member 250, the attachment fasteners 160 are visible to the end user, which may be an undesirable aesthetic. Thus, the fastener assembly 200 and the cover member 250 may be retrofit parts that are configured for use with the support bracket 110 to hide the support bracket 110 and the attachment fasteners 160 from view. This may be done without modifying any aspect of the support bracket 110, but instead simply adding the fastener assembly 200 which includes the washer component 230, and then adding the cover member 250 which is configured to be attached to the washer component 230 while hiding all fasteners in the system from view (including the attachment fasteners 160, the fastener component 210 and the washer component 230 of the fastener assembly 200, and perhaps also hiding the support bracket 110). In some embodiments, the fastener assembly 200 and the cover member 250 may be part of the original railing system, rather than being retrofit part.

[0062] While the foregoing description and drawings represent exemplary embodiments of the present disclosure, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. In addition, numerous variations in the methods / processes described herein may be made within the scope of the present disclosure. One skilled in the art will further appreciate that the embodiments may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the disclosure, which are particularly adapted to specific environments and operative requirements without departing from the principles described herein. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive. The appended claims should be construed broadly, to include other variants and embodiments of the disclosure, which may be made by those skilled in the art without departing from the scope and range of equivalents.

Claims

1. A railing system comprising:a post;a rail member; anda bracket assembly configured to couple the rail member to the post, the bracket assembly comprising:a support bracket configured to be attached to the post with one or more attachment fasteners, the support bracket configured to support at least an end portion of the rail member;at least one fastener assembly comprising a fastener component and a washer component, the fastener component configured to secure the washer component to an outer surface of the support bracket; anda cover member comprising an inner surface and at least one locking element protruding from the inner surface, the cover member configured to be placed into an installed position wherein the cover member covers the one or more attachment fasteners and the at least one fastener assembly, the at least one locking element of the cover member configured to engage the washer component of the fastener assembly to lock the cover member in the installed position.

2. The railing system according to claim 1 further comprising:the washer component comprising a rear surface that is configured to abut the outer surface of the support bracket and a front surface opposite the rear surface, the front surface comprising a washer cavity defined by an inner surface of the washer component and a floor, the floor comprising an opening;wherein the fastener component comprises a shank portion that is configured to extend through the opening in the floor of the washer cavity and into the support bracket and a head portion that is configured to nest within the washer cavity in contact with an upper surface of the floor.

3. The railing system according to claim 2 further comprising:the at least one locking element of the cover member being configured to pass over the front surface of the washer and engage the inner surface of the washer component during the placing of the cover member into the installed position.

4. The railing system according to claim 1 further comprising:the washer component comprising a rear surface that is configured to abut the outer surface of the support bracket, a front surface opposite the rear surface, an outer surface, and a flange protruding from the outer surface proximate the front surface;the cover member comprising at least one pair of track elements protruding from the inner surface of the cover member that collectively define a track channel, wherein when the cover member is in the installed position, the washer component is positioned within the track channel and a portion of each of the track elements of the at least one pair of track elements are located between the flange of the washer component and the outer surface of the support bracket.

5. The railing system according to claim 4 wherein the at least one locking element of the cover member is located withing the track channel.

6. The railing system according to claim 4 further comprising:the cover member comprising a bottom wall, a first side wall extending from the bottom wall, and a second side wall extending from the bottom wall;wherein the at least one locking element comprises a first locking element extending from the inner surface of the cover member along the first side wall and a second locking element extending from the inner surface of the cover member along the second side wall;wherein the at least one pair of track elements comprises a first pair of track elements located on the first side wall and a second pair of track elements located on the second side wall;wherein the at least one fastener assembly comprises a first fastener assembly comprising a first fastener component and a first washer component located on a first side of the rail member and a second fastener assembly comprising a second fastener component and a second washer component located on a second side of the rail member; andwherein when the cover member is in the installed position, the first pair of track elements at least partially surround the first washer component and the first locking element is engaged with the first washer component and the second pair of track elements at least partially surround the second washer component and the second locking element is engaged with the second washer component.

7. The railing system according to claim 1 further comprising:the support bracket comprising a bottom wall, a first side wall extending from the bottom wall, and a second side wall extending from the bottom wall;wherein the at least one fastener assembly comprises:a first fastener component and a first washer component, the first fastener component configured to be inserted through the first washer component and into the first side wall of the support bracket to secure the first washer component to the outer surface of the first side wall of the support bracket; anda second fastener component and a second washer component, the second fastener component configured to be inserted through the second washer component and into the second side wall of the support bracket to secure the second washer component to the outer surface of the second side wall of the support bracket.

8. The railing system according to claim 1 further comprising:the rail member being a T-rail having a lower portion having a first side outer surface and a second side outer surface and an upper portion having a first downwardly facing shoulder surface that protrudes beyond the first side outer surface of the lower portion and a second downwardly facing shoulder surface that protrudes beyond the second side outer surface of the lower portion;a top cover configured to wrap around the end portion of the upper portion of the rail member; andwherein the end portion of the lower portion of the rail member nests within a receiving cavity of the support bracket.

9. The railing system according to claim 8 wherein the cover member is configured to cover and enclose an entirety of the support bracket, the one or more attachment fasteners, and the at least one fastener assembly without covering and enclosing any part of the top cover.

10. The railing system according to claim 1 wherein the at least one locking element of the cover member is configured to engage the washer component of the at least one fastener assembly via a snap-fit connection.

11. The railing system according to claim 1 further comprising:the rail member comprising a longitudinal axis;wherein the cover member is configured to be slidably coupled to the fastener assembly by sliding the cover member in a first direction along the rail member towards the support bracket during which the at least one locking element of the cover member passes over a portion of a front end of the washer component and extends into a washer cavity of the washer component to lock the cover member to the fastener assembly, at which point the cover member is prevented from being slid in a second direction that is opposite the first direction.

12. A railing system comprising:a post;a rail member; anda bracket assembly configured to couple the rail member to the post, the bracket assembly comprising:a support bracket configured to be attached to the post with one or more attachment fasteners, the support bracket configured to support at least an end portion of the rail member;at least one fastener assembly comprising a fastener component and a washer component, the fastener component configured to secure the washer component to an outer surface of the support bracket; anda cover member comprising an inner surface and at least one pair of track elements protruding from the inner surface that collectively define a track channel, the cover member configured to be placed into an installed position wherein the cover member covers the one or more attachment fasteners and the at least one fastener assembly and the washer component nests within the track channel.

13. The railing system according to claim 12 further comprising:the washer component comprising a rear surface that is configured to abut the outer surface of the support bracket, a front surface opposite the rear surface, an outer surface, and a flange protruding from the outer surface proximate the front surface;wherein when the cover member is in the installed position, the washer component is positioned within the track channel and a portion of each of the track elements of the at least one pair of track elements are located between the flange of the washer component and the outer surface of the support bracket.

14. The railing system according to claim 13 further comprising:the at least one pair of track elements comprising a first track element and a second track element, each of the first and second track elements comprising a first wall that extends in a direction away from the inner surface of the cover member and a second wall that extends from the first wall, the second wall of the first and second track elements extending towards one another; andwherein when the cover member is in the installed position, the flange of the washer component is located within channels defined between the second wall of the first and second track elements and the inner surface of the cover member and the second wall of the first and second track elements is located between the flange of the washer component and the outer surface of the support bracket.

15. The railing system according to claim 12 further comprising:the washer component comprising a rear surface that is configured to abut the outer surface of the support bracket and a front surface opposite the rear surface, the front surface comprising a washer cavity defined by an inner surface of the washer component;the cover member comprising at least one locking protuberance extending from the inner surface of the cover member; andwherein during the placing of the cover member into the installed position, the at least one locking protuberance of the cover member passes over the front surface of the washer component and snaps into the washer cavity, thereby locking the cover member to the at least one fastener assembly in the installed position.

16. The railing system according to claim 15 wherein the cover member is configured to lockingly engage only the washer component when in the installed position.

17. The railing system according to claim 12 wherein the support bracket and the cover member are U-shaped, the cover member configured to cover and enclose the support bracket when in the installed position such that no portion of the support bracket, the one or more attachment fasteners, and the at least one fastener assembly is visible when the cover member is in the installed position.

18. A method of installing a railing system, the method comprising:attaching a support bracket to a post with one or more attachment fasteners;supporting an end portion of a rail member with the support bracket;securing a washer component to an outer surface of the support bracket; andsliding a cover member towards the support bracket until the cover member is in an installed position wherein the cover member covers and at least partially encloses the support bracket, the cover member comprising a locking protuberance that engages with the washer component to lock the cover member in the installed position.

19. The method according to claim 18 further comprising, during the sliding of the cover member, the locking protuberance of the cover member passing over a front surface of the washer component and snapping into a washer cavity defined by an inner surface of the washer component, the locking protuberance engaging the inner surface of the washer component to lock the cover member in the installed position.

20. The method according to claim 18 further comprising, during the sliding of the cover member, the washer component nesting within a track channel defined by a pair of track elements of the cover member, each of the pair of track elements comprising a locking wall portion that nests between a flange of the washer component and the outer surface of the support bracket when the cover member is in the installed position to further assist in locking the cover member in the installed position.

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