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  Hidden fastener guard rail systemUSPTO Application #: 20070012903Title: Hidden fastener guard rail system Abstract: A guard rail system available in kits ready for assembly is formed of a capped wood composite with the look and feel of wood. The system includes balusters fastened to an upper rail and a bottom rail, each of which are attached to a post or wall. The upper rail is formed of a plurality of pieces that fit together to form a circumferential finished surface and include a longitudinal cavity. Fasteners that couple the balusters to the upper rail and the upper rail to the posts, are not externally visible. The brackets that couple the upper rail to the posts are disposed within the longitudinal cavity. (end of abstract) Agent: Duane Morris, LLPIPDepartment - Philadelphia, PA, US Inventor: David J. Stucky USPTO Applicaton #: 20070012903 - Class: 256059000 (USPTO) Related Patent Categories: Fences, Rail The Patent Description & Claims data below is from USPTO Patent Application 20070012903. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] This invention relates to guard rail systems. In particular, this invention relates to a prefabricated guard rail system, components for a guard rail system and kits of components for a guard rail system that meets building code requirements. BACKGROUND [0002] Guard rails are used around decks, balconies, platforms, staircases and other elevated structures, to prevent injury and possible death from falling off of the edge of such structures. Most building codes have rigid requirements for guard rails, both in terms of where they are required and also prescribing certain construction parameters. [0003] There is a need for deck and porch railing products that offer the look and feel of wood, provide a maintenance-free finish, are easily and quickly installed, have minimal numbers of parts including pieces and hardware, and which meet building code requirements as above. [0004] Guard rail systems formed of wood, wood composites, various vinyl materials, and capped wood composites are available. Guard rail systems formed of capped wood composites are available in kits for easy installation whereas guard rail systems formed of wood or wood composites are fabricated at the job site and assembled using conventional wood practices, i.e., using screws and nails as fasteners. The fasteners used to assemble such railing systems are typically exposed, i.e., screw/nail heads are visible and aesthetically displeasing. Some vinyl guard rail systems such as PVC (polyvinyl chloride) systems are provided in kits, include pre-drilled holes and are easily assembled. A shortcoming of most vinyl systems, however, is that unsightly exposed metal brackets are typically used to secure the components of the guard rail system together. [0005] While PVC systems generally offer the advantage of kits, additional parts and pieces are also required to address installation concerns presented by angles and stairs which requires the manufacture of application specific components. Some PVC systems also use injection molded sleeves to hide the rail-to-post bracket connection. While the sleeves are generally effective at masking this connection, the sleeves and screws exposed to secure the sleeve to the rail detract from the appearance of the rail. Other PVC systems use routed slot-joint type systems to eliminate exposed fasteners, yet these components are prone to rattle and require numerous components with specific routing patterns to address various installation conditions, e.g. line post, corner post, end post, stair end post, stair thru post, and left and right stair to guard rail corners. Moreover, when grasped, hollow PVC over metal reinforcement rails feel hollow or plastic emphasizing the fact that the rail system is not formed of wood. [0006] Capped wood composite guard rail systems offer the advantage of being provided in kits yet also having the appearance and feel of wood. Systems having the appearance of wood are typically favored in the guard rail industry. Current capped wood guard rail systems require metal brackets to connect the rails to the posts. The metal brackets are typically fastened below the rail, remaining undesirably visible in the finished assembly and revealing that the guard rail system is not formed of wood. [0007] It would therefore be desirable to provide a guard rail system that has the look and feel of wood, yet is formed of materials that can be provided in kits for easy assembly, and which further include hidden fasteners not visible to the exterior. SUMMARY OF THE INVENTION [0008] To address these and other needs, and in view of its purposes, the present invention provides a guard rail system formed of various materials and which may be pre-cut in kits, including capped wood composite materials that give the appearance of wood. The system includes hidden fasteners and brackets that eliminate unsightly screw or nail heads and which undesirably reveal that the system is not made of wood. [0009] According to one aspect of the invention, provided is a guard rail system that includes an upper rail and a bottom rail affixed to at least two anchor members and a plurality of balusters affixed to the upper rail and lower rail. The upper rail comprises a plurality of cooperating longitudinal members and includes a longitudinal cavity therein. First fasteners that fasten the upper rail to the balusters are not externally visible and the upper rail is affixed to each of the anchor members by a bracket disposed completely within the longitudinal cavity and not externally visible. The anchor member may be a post or wall or other structure to which a rail may be attached or anchored. [0010] In another aspect of the invention, provided is a guard rail system that includes an upper rail and a bottom rail affixed to at least two anchor members and a plurality of balusters affixed to the upper rail and lower rail. The upper rail comprises a handrail superjacently joined to a top universal rail with a longitudinal cavity therebetween. First fasteners that fasten the upper rail to the balusters are not externally visible and the upper rail is affixed to each of the anchor members by a bracket disposed completely within the longitudinal cavity and not externally visible. The top universal rail has a cross-sectional shape of an upright U and is affixed to the balusters. [0011] In another aspect of the invention, provided is prepared kit for a guard rail system comprising an upper rail and a lower rail adapted to be coupled to at least two anchor members, a plurality of balusters adapted to be coupled to the upper rail and the lower rail, each baluster including a bore for receiving a fastener. The upper rail comprises a handrail and a top universal rail to be joined together, the handrail over the top universal rail, to form a longitudinal cavity therebetween. First fasteners that fasten the top universal rail to the balusters are not externally visible. Brackets that affix the upper rail to each of the anchor members are disposed completely within the longitudinal cavity and not externally visible. BRIEF DESCRIPTION OF THE DRAWING [0012] The present invention is best understood from the following detailed description when read in conjunction with the accompanying drawing. Like numerals denote like features throughout the specification and drawing. [0013] FIG. 1 is a cross-sectional side view of an exemplary guard rail system of the invention; [0014] FIG. 2 is a perspective view of a portion of the guard rail system of the invention including the hidden fastener; [0015] FIG. 3 is a perspective view of an exemplary fastener used in the guard rail system of the invention; [0016] FIG. 4 is a cross-sectional perspective view of an exemplary guard rail system of the invention; and [0017] FIGS. 5 and 6 are cross-sectional end views showing other exemplary embodiments of the guard rail system of the invention. DETAILED DESCRIPTION [0018] The present invention provides a guard rail system formed of various materials. The components may be formed of vinyl materials such as PVC, wood composites, or capped wood composites which may include a white or colored capstock over a wood composite core to produce a painted look. The finish of the external surfaces used for the upper rail, bottom rail, balusters, and post sleeve may be a wood grain finish that provides the look and feel of wood. The systems may come in kits which are pre-cut and may include pre-drilled holes for assembly. In one embodiment, any or all of the balusters, post sleeve, upper and lower rail components may be formed of a polymer wood composite such as a foamed polymer-fiber composite such as described in U.S. Pat. No. 6,344,268, issued to the present inventor as one of multiple inventors. The building materials described in U.S. Pat. No. 6,344,268 include, in one embodiment, a foamed polymer composite building material consisting of about 35-73 wt. % polyvinyl chloride (PVC) resin, about 27-65 wt. % fiber, a specific gravity of about 1.07 g/cc or less, and including a porosity of at least 1%. This exemplary foam polymer composite building material is capable of having a screw fastener countersunk therein without pre-drilling. U.S. Pat. No. 6,344,268 is hereby incorporated by reference, as it set forth in its entirety and the aforedescribed exemplary building material and the other building materials disclosed in U.S. Pat. No. 6,344,268 may be used as building materials of the present invention in various embodiments. [0019] An aspect of the present invention is that the guard rail system provides an aesthetically pleasing wood grain finish combined with hidden fasteners. Continue reading... Full patent description for Hidden fastener guard rail system Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Hidden fastener guard rail system patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Hidden fastener guard rail system or other areas of interest. ### Previous Patent Application: Safety fence and protection pole connection apparatus for trampoline Next Patent Application: Fence system Industry Class: Fences ### FreshPatents.com Support Thank you for viewing the Hidden fastener guard rail system patent info. 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