Cable railing system

Abstract

A cable railing system comprises post assemblies, with upper and lower railings extending between the post assemblies. The post assemblies have an upright member with a plurality of post openings through which cables may pass. Pickets extend between the upper and lower railings. The pickets comprise picket openings through which the cables may also pass. The lower railings have two lower lateral members separated by a lower transverse member. The pickets extend in between the two lower lateral members above the lower transverse member. The lower railings may be supported by lower supports. The pickets may be attached to the upper railing using picket connectors. The picket connectors comprise a connector plate that is adapted to connect to the upper railing. The picket connectors further comprise a pair of downward-extending projections to engage with the pickets and to hold the pickets in place within the upper railing.

Description

Cable Railing SystemTECHNICAL FIELD

[0001] The present disclosure relates to railing systems. In particular, the present disclosure relates to cable railing systems.BACKGROUND

[0002] Railing systems for any number of outdoor applications are known. For example, residential decks, pool decks, and yards all utilize any number of conventional railing systems. Such systems typically comprise a number of vertical posts with one or more railings extending between the posts. In some systems, there may be two railings, comprising an upper railing and a lower railing. A number of pickets may extend between the upper and lower railings. Alternatively, a number of panels may extend between the upper and lower railings.

[0003] Another such type of a railing system is a cable railing system. Cable railing systems comprise one or more cables that extend between the posts and are used for decks and other outdoor applications. The use of cables allows for greater visibility through the railing system, as the cables are typically fairly narrow (when compared, for example, with conventional pickets or panels used in other types of railing systems).

[0004] However, because cables are typically less rigid than pickets or panels, additional measures may need to be taken to ensure the stability and integrity of cable railing systems.SUMMARY

[0005] A cable railing system in accordance with one embodiment comprises a plurality of post assemblies, with upper and lower railings extending between adjacent ones of the post assemblies. The post assemblies comprise an upright member, with the upright member comprising a plurality of post openings through which cables may pass. One or more picketsextend at least between the upper and lower railings. The pickets comprise picket openings through which the cables may also pass.

[0006] The lower railings comprise two lower lateral members separated by a lower transverse member. The pickets extend in between the two lower lateral members above the lower transverse member. The lower railings may be supported by lower supports. The lower supports comprise a base that is attached to a surface. A leg extends from the base. A railing engagement portion extends from the leg and is adapted to engage with the lower railing. The railing engagement portion may comprise upward-extending support members, with support ledges extending inwardly from the support members.

[0007] The pickets may be attached to the upper railing using picket connectors. The picket connectors comprise a connector plate that is adapted to connect to the upper railing. The picket connectors further comprise a pair of downward-extending projections that are adapted to engage with the pickets and to hold the pickets in place within the upper railing.

[0008] The cable railing system may comprise post assemblies that are medial post assemblies (for planar or end portions of the cable railing system) and comer post assemblies (for comers of the cable railing system). The upright members of the post assemblies may comprise a rectangular cross-section, with four post faces arranged orthogonal to each other.

[0009] In the medial post assemblies, first and second post openings are located on two opposing post faces, such that the cables may extend across the upright member.

[0010] In the comer post assemblies, the first and second post openings are located on two adjacent post faces. An interior member is provided within the upright member, with the interior member providing a surface to allow the cables to transition 90 degrees between the two adjacent post faces.

[0011] In one embodiment, a cable railing system comprises at least one comer post assembly and a plurality of cables. The at least one comer post assembly comprises an upright member. The upright member comprises an elongated first face, an elongated second face connected to the first face, and an interior member. The first face comprises a plurality of first post openings, with the plurality of first post openings aligned. The second face comprises a plurality of second post openings, with the plurality of second post openingsaligned. The interior member extends between the first face and the second face, with the interior member extending along at least a portion of the first face and the second face along a longitudinal axis of the upright member. Each of the plurality of cables extends through one of the plurality of first post openings and one of the plurality of second post openings, and engages the interior member.

[0012] In another embodiment, a railing system comprises one or more elongated upper railings, one or more elongated lower railings, and one or more lower supports. At least one of the one or more lower railings comprises an elongated lower transverse member and two elongated lower lateral members. The two elongated lower lateral members are attached to the lower transverse member, with each of the two lower lateral members comprising an elongated first ledge below the lower transverse member. The first ledges of the two lower lateral members extend towards each other. At least one of the one or more lower supports comprises a base, a leg extending from the base, and a railing engagement portion extending from the leg. The railing engagement portion is located between the two lower lateral members and engages with the first ledges of the two lower lateral members.

[0013] In still another embodiment, a railing system comprises one or more elongated upper railings, one or more elongated lower railings, one or more pickets, and one or more picket connectors. At least one of the one or more upper railings comprises two upper lateral portions and an upper transverse member extending between the two upper lateral portions to define, at least in part, an upper channel. Each of the one or more pickets comprises an upper picket end. Each of the one or more pickets extends between the one or more upper and the one or more lower railings. At least one of the one or more picket connectors comprises a connector plate adapted to be secured to the upper transverse member and two projections extending away from the connector plate. The two projections engage with the upper end of one of the one or more pickets, and the at least one of the one or more picket connectors is located within the upper channel.

[0014] The foregoing was intended as a summary only and of only some of the aspects. It was not intended to define the limits or requirements of the present disclosure. Other aspects will be appreciated by reference to the detailed description set out below.BRIEF DESCRIPTION OF DRAWINGS

[0015] The embodiments of the present disclosure will be described by reference to the drawings thereof, in which:

[0016] Fig. 1 depicts a cable railing system in accordance with one embodiment;

[0017] Fig. 2 is a partial view of the cable railing system of Fig. 1;

[0018] Fig. 3 is another partial view of the cable railing system of Fig. 1;

[0019] Fig. 4 is a partial view of a medial post assembly;

[0020] Fig. 5 is a partial view of a comer post assembly;

[0021] Fig. 6 is atop view of the comer post assembly of Fig. 5;

[0022] Fig. 7 is a partial view of the cable railing system;

[0023] Fig. 8 is a partial view of the upper railing;

[0024] Fig. 9 is an exploded partial view of the cable railing system;

[0025] Fig. 10 is a cross-sectional partial view of the cable railing system;

[0026] Fig. 11 depicts a picket connector;

[0027] Fig. 12 is a partial view of a lower railing;

[0028] Fig. 13 is a magnified partial view of the lower railing;

[0029] Fig. 14 is a cross-sectional partial view of the cable railing system;

[0030] Fig. 15 is a partial view of a spacer;

[0031] Fig. 16 is a cross-sectional partial view of the cable railing system;

[0032] Fig. 17 depicts a lower support; and

[0033] Fig. 18 depicts a lacing needle.DETAILED DESCRIPTION

[0034] Referring to Figs. 1 to 3, a cable railing system 10 comprises a plurality of post assemblies 12 spaced apart from each other. The cable railing system 10 further comprises one or more upper railings 14 and one or more lower railings 16. The upper railings 14 may be spaced apart from the lower railings 16. The post assemblies 12 and the upper and lower railings 14, 16 may be constructed from metal or some other suitable material. In some embodiments, one of the upper railings 14 and one of the lower railings 16 may extend between two adjacent ones of the post assemblies 12. The post assemblies 12 may be fixedly attached to a surface 2 (such as a deck, some other suitable structure, or the ground) using fasteners or the like. A distance between adjacent ones of the post assemblies 12 may depend, at least in part, on local building codes that specify a maximum distance between adjacent ones of the post assemblies 12. In some embodiments, the distance between adjacent ones of the post assemblies 12 may be approximately four feet. In other embodiments, the distance between adjacent ones of the post assemblies 12 may be approximately six feet.

[0035] Referring to Fig. 4, at least one of the post assemblies 12 may comprise an elongated upright member 18. The upright member 18 may comprise a plurality of elongated faces 20. In some embodiments, the upright member 18 may comprise four faces 20 (i.e. first face 22, second face 24, third face 26, and fourth face 28) that are connected together. For example, the first face 22 may be connected to the second face 24 and the fourth face 28, the second face 24 may be connected to the third face 26 and the first face 22, the third face 26 may be connected to the fourth face 28 and the second face 24, and the fourth face 28 may be connected to the first face 22 and the third face 26. In some embodiments, the faces 20 may define a generally rectangular cross-section. In some other embodiments, the face 20 may define a generally square cross-section.

[0036] The post assembly 12 may also comprise one or more upper post attachment members 34 connected to the upright member 18. The upper post attachment members 34 may be adapted to connect adjacent ones of the upper railings 14 to the upright member 18. Forexample, in the embodiment shown in Fig. 2, the post assembly 12 comprises one upper post attachment member 34 that may extend around at least a portion of perimeters of each of two adjacent ones of the upper railings 14 in order to secure the adjacent ones of the upper railings 14 to an upper end 30 of the upright member 18.

[0037] The post assembly 12 may also comprise one or more lower post attachment members 36 connected to the upright member 18. The lower post attachment members 36 may be adapted to connect adjacent ones of the lower railings 16 to the upright member 18. For example, in the embodiment shown in Fig. 2, the post assembly 12 comprises two lower post attachment members 36, with each of the two lower post attachment members 36 adapted to support from below one of the two adjacent lower railings 16 and to secure the one of the two adjacent lower railings 16 proximate to a lower end 32 of the upright member 18.

[0038] It is understood that other mechanisms for attaching the upper and lower railings 14, 16 to the upright member 18 are also possible, such as through brackets, fasteners, adhesives, or the like.

[0039] The cable railing system 10 further comprises a plurality of cables 38 extending between and / or through the post assemblies 12. The number of cables 38 may depend, at least in part, on local building codes that specify a minimum vertical spacing between adjacent ones of the cables 38. The minimum spacing may also take into account an amount of deflection possible with the cables 38. In the embodiment shown in Fig. 1, the number of cables 38 may be eleven. It is understood that a greater or smaller number of the cables 38 are also possible.

[0040] In some embodiments, the cables 38 may extend between two adjacent ones of the post assemblies 12. In other embodiments, the cables 38 may extend through one or more of the post assemblies 12. In such embodiments, the cables 38 may span across more than one of the post assemblies 12.

[0041] Referring to Fig. 1, the cable railing system 10 may take a variety of shapes. For example, the cable railing system 10 may be used to provide a barrier extending in a single plane. However, the cable railing system 10 may also be used to provide a barrier that has one or more comers (e.g. a L-shaped barrier or a rectangular enclosure). In order to provide such shapes, the post assemblies 12 may comprise medial post assemblies 40 and comer postassemblies 100. The medial post assemblies 40 may be used for portions of the cable railing system 10 that extends in a single plane or at the ends of the cable railing system 10, whereas the comer post assemblies 100 may be used at the comers of the cable railing system 10. For example, in the embodiment shown in Fig. 1, the cable railing system 10 comprises three of the medial post assemblies 40 and one of the comer post assemblies 100.

[0042] Fig. 4 depicts one embodiment of the medial post assembly 40. The upright member 18 for the medial post assembly 40 may comprise a plurality of first post openings 42 and a plurality of second post openings 44. The first and second post openings 42, 44 are sized to allow the cables 38 to pass therethrough. The plurality of first post openings 42 may be arranged along one of the faces 20 (e.g. the first face 22), with the plurality of second post openings 44 arranged along the opposing one of the faces 20 (i.e. the third face 26). The first and second post openings 42, 44 may be substantially aligned along a longitudinal axis of the respective faces 20 on which they are arranged. For example, all of the first post openings 42 may be substantially vertically aligned along the first face 22, while all of the second post openings 44 may be substantially vertically aligned along the third face 26.

[0043] Each of the first post openings 42 may correspond to one of second post openings 44. For example, in some embodiments, each of the first post openings 42 may correspond to one of second post openings in distance from the upper end 30. In some embodiments, the first and second post openings 42, 44 may be arranged such that distances between adjacent ones of the first post openings 42 correspond to distances between adjacent ones of the second post openings 44. In yet other embodiments, the first and second post openings 42, 44 may be arranged such that when the cables 38 extend therethrough, a spacing between adjacent ones of the cables 38 is similar along a height of the upright member 18. In Fig. 4, only one of the cables 38 is shown; however, it is understood that others ones of the cables 38 may extend through others ones of the first and second post openings 42, 44.

[0044] In some embodiments, the first and second post openings 42, 44 may have diameters that are larger than the diameters of the cables 38 in order to allow the cables 38 to pass therethrough. As the cables 38 are able to pass through the first and third faces 22, 26, the cables 38 passing through the medial post assembly 40 are able to define a substantially planar, vertical barrier through the medial post assembly 40.

[0045] When the medial post assembly 40 is located at one end of the cable railing system 10, the cables 38 may pass through the first post openings 40 and terminate. For example, a stopper may be attached to one end of each of the cables 38. The stopper may have a diameter greater than a diameter of the first post opening 40. This allows the cable 38 to be secured to the upright member 18 (i.e. the end of the cable 38 is unable to exit from the upright member 18). In some embodiments, for the medial post assemblies 40 located at the ends of the cable railing system 10, the second post openings 44 may be omitted.

[0046] When the medial post assembly 40 is located between the ends of the cable railing system 10, the cables 38 may pass through the first post openings 42 located on the first face 22 and the second post openings 44 located on the third face 26. In this manner, the cables 38 may pass through one or more of the post assemblies 12. In other words, a length of the cables 38 may be greater than a distance between two adjacent ones of the post assemblies 12.

[0047] Figs. 5 and 6 depict one embodiment of the comer post assembly 100. The comer post assembly 100 is similar in some aspects to the medial post assembly 40. The upright member 18 for the comer post assembly 100 may comprise at least two of the faces 20 (e.g. the first face 22 and the second face 24) that are connected together. In some embodiments, the upright member 18 comprises four of the faces 20 (e.g. the first face 22, the second face 24, the third face 26, and the fourth face 28) that are connected together to define a generally rectangular cross-section. In embodiments where the upright member 18 comprises four of the faces 20, the faces 20 may generally define, at least in part, an enclosure 102.

[0048] The first post openings 42 and the second post openings 44 on the comer post assembly 100 are located on adjacent ones of the faces 20 (e.g. the first face 22 and the second face 24, respectively). The alignment and spacing of the first post openings 42 and the second post openings 44 for the comer post assembly 100 may be similar to that for the medial post assembly 40.

[0049] In some embodiments, the first face 22 and the second face 24 are oriented substantially perpendicularly to each other, such that the first post openings 42 and the second post openings 44 are oriented approximately 90 degrees to each other. The cables 38 may extend through the first post openings 42 and the second post openings 44.

[0050] Referring to Figs 5 and 6, the upright member 18 for the comer post assembly 100 further comprises an elongated interior member 104 extending from the first and second faces 22, 24. In some embodiments, at least a portion of the interior member 104 may be curved. The interior member 104 comprises first and second edges 106, 108, with the first edge 106 attached to the first face 22 and the second edge 108 attached to the second face 24. The first edge 106 extends along a substantially longitudinal axis of the first face 22, and the second edge 108 extends along a substantially longitudinal axis of the second face 24.

[0051] The interior member 104 comprises inner and outer surfaces 110, 112 extending between the first and second edges 106, 108. The cables 38 are able to engage with the outer surface 112 as they transition from the first post openings 42 on the first face 22 to the second post openings 44 on the second face 24 within the upright member 18. The interior member 104 may extend for substantially an entire height of the upright member 18. In some embodiments, the interior member 104 may extend for at least a portion of the upright member 18 along which the first and second post openings 42, 44 are located.

[0052] The outer surface 112 provides a surface for the cables 38 to form a bend within the upright member 18. When the interior member 104 is curved, the outer surface 112 allows the cables 38 to form a curved bend within the upright member 18. By providing the outer surface 112 for the cables 38 to form a bend within the upright member 18, the cables 38 are able to extend through the comer post assembly 100, instead of having the cables 38 terminate at the first and second post openings 42, 44. In Fig. 5, only one of the cables 38 is shown; however, it is understood that others ones of the cables 38 may extend through others ones of the first and second post openings 42, 44.

[0053]

[0054] The first edge 106 may be offset from the first post openings 42 to allow the cables 38 to pass through the first post openings 42 and to engage the outer surface 112 without being blocked by the outer surface 112. The second edge 108 may be offset from the second post openings 44 to allow the cables 38 to pass through the second post openings 44 and to engage the outer surface 112 without being blocked by the outer surface 112.

[0055] In some embodiments, the interior member 104 may comprise elongated first and second dimpled portions 114, 116 proximate to the first and second edges 106, 108,respectively. The first and second dimpled portions 114, 116 may extend for substantially an entire height of the interior member 104. In some embodiments, the first and second dimpled portions 114, 116 may extend for at least a portion of the interior member 104 corresponding to a portion of the upright member 18 for which along which the first and second post openings 42, 44 are located. The first and second dimpled portions 114, 116 may define indented regions along the otherwise substantially smooth interior member 104. The first and second dimpled portions 114, 116 assist when guiding the cables 38 through the first and second post openings 42, 44, as described later.

[0056] By providing the interior member 104 in the comer post assemblies 100 and by having the first and second post openings 42, 44 on opposing ones of the faces 20 in the medial post assemblies 40, it is possible for the cables 38 to extend through or around multiple ones of the post assemblies 12. In some embodiments, it may be possible for the cables 38 to extend across an entirety of the cable railing system 10, instead of having shorter segments of the cables 38 extend for portions of the cable railing system 10.

[0057] The cable railing system 10 further comprises one or more pickets 46 extending at least between the upper and lower railings 14, 16. The pickets 46 comprise upper and lower picket ends 48, 50 and one or more picket openings 52 located between the upper and lower picket ends 48, 50. The picket openings 52 are sized to allow the cables 38 to pass therethrough. The picket openings 52 help to maintain proper spacing between the cables 38 between the post assemblies 12 and to prevent sagging of the cables 38 between the post assemblies 12.

[0058] Referring to Figs. 7 and 8, at least one of the upper railings 14 may comprise a pair of elongated upper lateral portions 200. In some embodiments, one or both of the upper lateral portions 200 may have a generally U-shaped configuration. The upper railing 14 may further comprise an elongated upper transverse member 202 extending between the upper lateral portions 200. The upper lateral portions 200 and the upper transverse member 202 generally define, at least in part, an elongated upper channel 204 that is adapted and sized to receive the upper picket ends 48 of the pickets 46.

[0059] The cable railing system 10 further comprises one or more picket connectors 206 for holding the pickets 46 in place within the upper channel 204.

[0060] Fig. 11 depicts one embodiment of the picket connectors 206. The picket connector 206 comprises a connector plate 208 that may be connected to the upper transverse member 202. The connector plate 208 may be substantially planar and may be sized to snugly fit within the upper channel 204. The connector plate 208 may comprise one or more plate openings 210 that may receive plate fasteners 212 therethrough for connecting the connector plate 208 to the upper transverse member 202. In some embodiments, the plate fasteners 212 may be self-drilling screws for securing the connector plate 208 to the upper transverse member 202. By using self-drilling screws as the plate fasteners 212, it may not be necessary to have openings for the plate fasteners 212 on the upper transverse member 202.

[0061] The picket connector 206 further comprises two projections 214 extending from the connector plate 208 and spaced apart from each other. Each of the projections 214 may be curved or bent. For example, as shown in Fig. 11, each of the two projections 214 may comprise first and second projection members 216, 218 connected to each other, with the first projection member 216 of the two projections 214 angled towards each other and the second projection member 218 of the two projections 214 angled away from each other. In some embodiments, a minimum distance between the two projections 214 is approximately the same as or less than a width of the upper picket end 48. The two projections 214 are adapted to engage with the upper picket end 48 of one of the pickets 46 and to hold the picket 46 in place within the upper channel 204. In some embodiments, the two projections 214 may be aligned along a longitudinal axis of the upper channel 204.

[0062] In some embodiments, the connector plate 208 may comprise at least two plate openings 210, with at least one of the plate openings 210 located on either side of the two projections 214.

[0063] Referring to Figs. 9 and 10, when the upper picket end 48 of the picket 46 is inserted between the projections 214, the engagement of the upper picket end 48 with each of the projections 214 will tend to cause the projections 214 to spread apart from each other, especially when the upper picket end 48 engages the intersection of the first and second projection members 216, 218 (which is where a distance between the two projections 214 may be at a minimum). Accordingly, the two projections 214 may tend to squeeze the picket46 proximate to the upper picket end 48, thereby holding the picket 46 in place within the upper channel 204.

[0064] The upper railing 14 may further comprise a handrail portion 220 connected to the upper lateral portions 200. The handrail portion 220 may be adapted to be gripped by a user and may include one or more curvatures to promote gripping by the user.

[0065] By using the picket connectors 206 to secure the pickets 46 to the upper railing 14, it is not necessary to drill or punch openings in the upper railing 14 (such as on the upper transverse member 202) for connecting the pickets 46 to the upper railing 14. The picket connectors 206 allow for the pickets 46 to be connected to the upper railing 14, albeit indirectly. The picket connectors 206 may be hidden from view within the upper channel 204 by the upper lateral portions 200, as shown in Fig. 7.

[0066] Referring to Figs. 12 and 13, at least one of the lower railings 16 comprises two elongated lower lateral members 300 and an elongated lower transverse member 302 extending between the two lower lateral members 300, thereby forming substantially an H- shape configuration. Each of the two lower lateral members 300 comprises upper and lower lateral ends 304, 306.

[0067] Each of the two lower lateral members 300 may further comprise an elongated first ledge 307, with the first ledges 307 of the two lower lateral members 300 extending inwardly towards each other. The first ledges 307 may be located between the lower transverse member 302 and the lower lateral ends 306. The first ledges 307 on the two lower lateral members 300 may be vertically aligned with each other.

[0068] Each of the two lower lateral members 300 may further comprises an elongated second ledge 308, with the second ledges 308 of the two lower lateral members 300 extending inwardly towards each other. The second ledges 308 may be located proximate to the lower lateral ends 306 of the two lower lateral members 300. In some embodiments, the second ledges 308 may be located above the lower lateral ends 306 of the two lower lateral members 300. The second ledges 308 on the two lower lateral members 300 may be vertically aligned with each other.

[0069] Referring to Fig. 14, the cable railing system 10 further comprises one or more lower supports 324 for supporting the lower railing 16 on the surface 2. In some embodiments, the lower supports 324 may be located generally beneath the pickets 46. However, it is understood that in other embodiments, the lower supports 324 may not necessarily be located beneath the pickets 46. Referring to Fig. 17, at least one of the lower supports 324 comprises a base 326, a leg 328 extending from the base 326, and a railing engagement portion 330 extending from the leg 328. The base 326 may be secured to the surface 2 using base fasteners 332 (e.g. screws, bolts, nails, or the like). Accordingly, the base 326 may comprise one or more base openings 334 that are adapted to receive the base fasteners 332 therethrough for securing the base 326 to the surface 2.

[0070] The railing engagement portion 330 may engage the lower railing 16. In some embodiments, one or both of the base 326 and the leg 328 may be substantially planar. The railing engagement portion 320 may be substantially U-shaped.

[0071] The railing engagement portion 320 may comprise a central portion 336 and two support members 338 extending from the central portion 336. The two support members 338 may extend upwardly from the central portion 336. In some embodiments, the railing engagement portion 320 may comprise two support ledges 340 extending from the support members 338 inwardly towards each other. Accordingly, in some embodiments, the railing engagement portion 330 may be substantially U-shaped or C-shaped.

[0072] The railing engagement portion 330 is adapted to engage with the lower railing 16. In some embodiments, the two support members 338 fit between the first ledges 307 and the second ledges 308 of the two lower lateral members 300.

[0073] In some embodiments, the two support members 338 engage with the lower lateral members 300 of the lower railing 16 between the first ledges 307 and the second ledges 308. In some embodiments, the two support members 338 are able to slide between the two lower lateral members 300, with each of the support members 338 engaging against one of the lower lateral members 300 between the first ledge 307 and the second ledge 308. In some embodiments, the support ledges 340 may engage against the first ledges 307, as best shown in Fig. 16. In still other embodiments, the central portion 336 may engage with the second ledge 308 while the support ledges 340 engage with the first ledges 307. The engagement of the support ledges 340 against the first ledges 307 may assist in supporting the lower railing16 above the surface 2. Furthermore, the second ledges 308 may prevent the lower railing 16 may being vertically removed from the lower supports 324.

[0074] Each of the two lower lateral members 300 may further comprises elongated third and fourth ledges 310, 312, with the third and fourth ledges 310, 312 of the two lower lateral members 300 extending inwardly towards each other. The third ledges 310 may be located proximate to the upper lateral ends 304. Each of the third and fourth ledges 310, 312 are spaced apart from each other and define, at least in part, an elongated groove 309 that may be located proximate to the upper lateral ends 304 of the two lower lateral members 300. In some embodiments, the grooves 309 may be located below the upper lateral ends 304 of the two lower lateral members 300. The grooves 309 on the two lower lateral members 300 may be vertically aligned with each other.

[0075] Referring to Fig. 14, the pickets 46 may extend into the lower railing 16, past the upper lateral ends 304 of the two lower lateral members 300. The pickets 46 may extend, at least partially, in between the two lower lateral members 300. In some embodiments, the lower picket ends 50 of the pickets 46 may rest on the lower transverse member 302; however, in other embodiments, the pickets 46 may be suspended above the lower transverse member 302 (e.g. through the cables 38 holding the pickets 46 above the lower transverse member 302 through the picket openings 52). Where the pickets 46 are suspended above the lateral transverse member 302, the pickets 46 may not require any physical support from the lower railing 16. This reduces the structural requirements of the lower railing 16 and allows the lower railing 16 to be constructed simpler and less costly. In some embodiments, the pickets 46 are able to snugly fit in between the respective third and / or fourth ledges 310, 312 of the two lower lateral members 300 through friction fitting, as best shown in Fig. 16.

[0076] Referring to Fig. 15, the cable railing system 10 may further comprise one or more elongated spacers 314 that are adapted to slide between the two lower lateral members 300 between adjacent ones of the pickets 46. At least one of the spacers 314 may comprise a central spacer portion 316 and two wing portions 318 extending from the central spacer portion 316. The central spacer portion 316 may be substantially planar. At least a portion of the wing portions 318 may be adapted to fit within the grooves 309.

[0077] In some embodiments, each of the two wing portions 318 may comprise an arm 320 extending from the central spacer portion 316. The wing portion 318 may further comprise a shoulder 322 extending from the arm 320. The shoulder 322 may be adapted and sized to fit within the groove 309. When the spacer 314 is inserted into the lower railing 16 (i.e. when the shoulders 322 are inserted into the grooves 309), the central spacer portion 316 and the lower lateral members 300 may form a substantially continuous surface.

[0078] Referring to Fig. 18, the cables 38 may be inserted through the comer post assemblies 100 using a lacing needle 400. The lacing needle 400 comprises first and second needle ends 402, 404. In some embodiments, the lacing needle 400 may be curved and comprises a needle channel 406 extending therethrough. One of the first and second needle ends 402, 404 may receive one of the ends of one of the cables 38 by insertion of a portion of the cable 38 into the needle channel 406. For example, the portion of the cable 38 may be inserted into the first needle end 402.

[0079] The needle channel 406 may be sized such that the portion of the cable 38 is able to remain secured within the needle channel 406 through friction fitting. Once the portion of the cable 38 has been attached to the first needle end 402, the second needle end 404 of the lacing needle 4000 (with the cable 38 attached) may be inserted through one of the first post openings 42. Because of the curved shape of the lacing needle 400, the second needle end 404 may come into contact with the first dimpled portion 114. By exerting further force on the lacing needle 400, the second needle end 404 may be guided past the first dimpled portions 110 and along the outer surface 112. When the second needle end 404 moves beyond the second edge 108, the second needle end 404 may be inserted through the corresponding one of the second post openings 44. By pushing the lacing needle 400 through the corresponding one of the second post openings 44, the cable 38 is able to be threaded through one of the first post openings 42 and the corresponding one of the second post openings 44. Once the first needle end 402 passes through the corresponding one of the second post openings 44, the lacing needle 400 may then be removed from the cable 38 by pulling the cable 38 from the first needle end 402.

[0080] The cable railing system 10 may be installed as follows. The post assemblies 12 (including the comer post assemblies 100 and the medial post assemblies 40) may be located and secured to the surface 2 using fasteners or the like. The picket connectors 206 may beattached to the upper railings 14 using the plate fasteners 212. The pickets 46 can then be inserted into the picket connectors 206. Each of the upper railings 14 may be secured between two of the post assemblies 12 using the upper post attachment members 34. One or more of the lower supports 324 may be inserted between the lower lateral members 300 of the lower railings 16. One or more of the spacers 314 may also be inserted between the lower lateral members 300 of the lower railings 16. Once the lower supports 324 and the spacers 314 have been inserted, the lower railings 16 may be secured between two of the post assemblies 12 using the lower post attachment members 36. Each of the lower railings 16 may be secured between two of the post assemblies 12 using the lower post attachment members 36. The lower supports 324 may be secured to the surface 2 using the base fasteners 332.

[0081] It will be appreciated by those skilled in the art that the preferred embodiments have been described in some detail but that certain modifications may be practiced without departing from the principles of the invention.

Claims

CLAIMS1. A cable railing system comprising: at least one comer post assembly, the at least one comer post assembly comprising an upright member, the upright member comprising: an elongated first face comprising a plurality of first post openings, wherein the plurality of first post openings are aligned; an elongated second face connected to the first face, the second face comprising a plurality of second post openings, wherein the plurality of second post openings are aligned; and an interior member extending between the first face and the second face, the interior member extending along at least a portion of the first face and the second face along a longitudinal axis of the upright member; a plurality of cables, wherein each of the plurality of cables extends through one of the plurality of first post openings and one of the plurality of second post openings, and engages the interior member; an elongated upper railing extending from the at least one comer post assembly, the upper railing comprising: two upper lateral portions; and an upper transverse member extending between the two upper lateral portions to define, at least in part, an upper channel; an elongated lower railing extending from the at least one comer post assembly, the lower railing comprising: an elongated lower transverse member; and two elongated lower lateral members attached to the lower transverse member, each of the two lower lateral members comprising an elongated first ledge below the lower transverse member, wherein the first ledges of the two lower lateral members extend towards each other; one or more lower supports, at least one of the one or more lower supports comprising: a base; a leg extending from the base; anda railing engagement portion extending from the leg, the railing engagement portion located between the two lower lateral members and engaging with the first ledges of the two lower lateral members; one or more pickets, wherein each of the one or more pickets comprises an upper picket end, and wherein each of the one or more pickets extends between the upper and the lower railings; and one or more picket connectors, wherein at least one of the one or more picket connectors comprises: a connector plate adapted to be secured to the upper transverse member; and two projections extending away from the connector plate; wherein the two projections engage with the upper end of one of the one or more pickets, and wherein the at least one of the one or more picket connectors is located within the upper channel.

2. The cable railing system of claim 1, wherein at least one of the one or more pickets comprises a plurality of picket openings, wherein the plurality of cables extend through the plurality of picket openings.

3. A railing system comprising: one or more elongated upper railings, wherein at least one of the one or more upper railings comprises: two upper lateral portions; and an upper transverse member extending between the two upper lateral portions to define, at least in part, an upper channel; one or more elongated lower railings, wherein at least one of the one or more lower railings comprises: an elongated lower transverse member; two elongated lower lateral members attached to the lower transverse member, each of the two lower lateral members comprising an elongated first ledge below the lower transverse member, wherein the first ledges of the two lower lateral members extends towards each other; one or more lower supports, at least one of the one or more lower supports comprising: a base;a leg extending from the base; and a railing engagement portion extending from the leg, the railing engagement portion located between the two lower lateral members and engaging with the first ledges of the two lower lateral members; one or more pickets, wherein each of the one or more pickets comprises an upper picket end, and wherein each of the one or more pickets extend between the one or more upper railings and the one or more lower railings; and one or more picket connectors, wherein at least one of the one or more picket connectors comprises: a connector plate adapted to be secured to the upper transverse member; and two projections extending away from the connector plate; wherein the two projections engage with the upper end of one of the one or more pickets, and wherein the at least one of the one or more picket connectors is located within the upper channel.

4. A cable railing system comprising: at least one comer post assembly, the at least one comer post assembly comprising an upright member, the upright member comprising: an elongated first face comprising a plurality of first post openings, wherein the plurality of first post openings are aligned; an elongated second face connected to the first face, the second face comprising a plurality of second post openings, wherein the plurality of second post openings are aligned; and an interior member extending between the first face and the second face, the interior member extending along at least a portion of the first face and the second face along a longitudinal axis of the upright member; a plurality of cables, wherein each of the plurality of cables extends through one of the plurality of first post openings and one of the plurality of second post openings, and engages the interior member.

5. The cable railing system of claim 4, wherein at least two of the plurality of cables are parallel to each other.

6. The cable railing system of claim 4,wherein a distance between an upper end of the upright member and each one of the plurality of first post openings defines a plurality of first heights; wherein a distance between the upper end of the upright member and each of the plurality of second post openings defines a plurality of second heights; and wherein, for each one of the plurality of first heights, there is a corresponding one of the plurality of second heights that is substantially the same.

7. The cable railing system of claim 4, wherein the interior member is curved.

8. The cable railing system of claim 4, wherein the interior member further comprises: a first edge, wherein the first edge is attached to the first face; a second edge, wherein the second edge is attached to the second face; an elongated first dimpled portion proximate to the first edge; and an elongated second dimpled portion proximate to the second edge.

9. The cable railing system of claim 4, wherein the upright member further comprises: an elongated third face connected to the second face; and an elongated fourth face connected to the third face and the first face.

10. The cable railing system of claim 9, wherein the upright member has a substantially rectangular cross-section.

11. A railing system comprising: one or more elongated upper railings; one or more elongated lower railings, wherein at least one of the one or more lower railings comprises: an elongated lower transverse member; and two elongated lower lateral members attached to the lower transverse member, each of the two lower lateral members comprising an elongated first ledge below the lower transverse member, wherein the first ledges of the two lower lateral members extend towards each other; and one or more lower supports, at least one of the one or more lower supports comprising: a base;a leg extending from the base; and a railing engagement portion extending from the leg, the railing engagement portion located between the two lower lateral members and engaging with the first ledges of the two lower lateral members.

12. The railing system of claim 11, wherein the base comprises one or more base openings.

13. The railing system of claim 12, wherein the one or more base openings are adapted to receive one or more fasteners, and wherein the one or more fasteners are adapted to secure the base to a surface.

14. The railing system of claim 11, wherein the railing engagement portion is substantially C-shaped.

15. The railing system of claim 11, wherein the railing engagement portion further comprises: a substantially planar central portion extending from the leg; two support members extending from the central portion; and a support ledge extending from each of the two support members, wherein the support ledges extend towards each other.

16. The railing system of claim 15, wherein the central portion engages with the first ledges of the two lower lateral members.

17. The railing system of claim 15, wherein each of the two lower lateral members further comprises an elongated second ledge below the first ledge.

18. The railing system of claim 17, wherein each of the two support members engages with one of the two lower lateral members between the first and second ledges.

19. The railing system of claim 11 further comprising one or more pickets, wherein each of the one or more pickets comprises a lower picket end, and wherein each of the one or more pickets extend between the one or more upper railings and the one or more lower railings.

20. The railing system of claim 19, wherein each of the lower lateral members further comprises: elongated third and fourth ledges; wherein the third and fourth ledges are above the lower transverse member; and wherein the third ledge is spaced apart from the fourth ledge to define, at least in part, a groove.

21. The railing system of claim 19, wherein the lower railing is adapted to receive the lower picket end of at least one of the one or more pickets between the two lower lateral members.

22. The railing system of claim 20 further comprising one or more spacers, wherein at least one of the one or more spacers comprises: a central spacer portion; and two wing portions extending from the central portion, wherein each of the two wing portions are adapted to engage with one of the grooves.

23. A railing system comprising: one or more elongated upper railings, wherein at least one of the one or more upper railings comprises: two upper lateral portions; and an upper transverse member extending between the two upper lateral portions to define, at least in part, an upper channel; one or more elongated lower railings; one or more pickets, wherein each of the one or more pickets comprises an upper picket end, and wherein each of the one or more pickets extends between the one or more upper and the one or more lower railings; and one or more picket connectors, wherein at least one of the one or more picket connectors comprises: a connector plate adapted to be secured to the upper transverse member; and two projections extending away from the connector plate;wherein the two projections engage with the upper end of one of the one or more pickets, and wherein the at least one of the one or more picket connectors is located within the upper channel.

24. The railing system of claim 23, wherein the connector plate comprises one or more plate openings.

25. The railing system of claim 24, wherein the one or more plate openings are adapted to receive one or more plate fasteners for securing the connector plate to the upper transverse member.

26. The railing system of claim 23, wherein each of the two projections is curved.

27. The railing system of claim 23, wherein each of the two projections deforms when engaged with the upper picket end of the one of the one or more pickets.

28. The railing system of claim 23, wherein the two projections squeeze the one of the one or more pickets proximate to the upper picket end.

29. The railing system of claim 23, wherein the at least one of the one or more upper railings further comprises a handrail portion, wherein the handrail portion is connected to the two upper lateral portions.

30. The railing system of claim 29, wherein the handrail portion is curved.

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