User assemblable picket rail panel

Abstract

A knockdown railing system includes a top rail assembly with a top rail that has a transverse wall, a first side wall and a second side wall each extending from the transverse wall. The transverse wall defines a plurality of openings disposed spaced apart along a length of the transverse wall, and the top rail further includes a first locking ledge extending from the first side wall and a second locking ledge extending from the second side wall. A plurality of picket plugs each include a pair of locking lugs in engagement with the first and second locking ledges of the top rail, and each of the plurality of picket plugs has a picket-insertable portion configured to be aligned with one of the plurality of openings in the transverse wall of the top rail. A rail cap is coupled to the top rail and conceals the plurality of picket plugs. Each of a plurality of pickets is configured to receive the picket-insertable portion of a respective one of the plurality of picket plugs. A bottom rail is configured to couple to the plurality of pickets.

What is claimed is: 
     
         1 . A knockdown railing system, comprising:
 a top rail assembly, comprising:
 a top rail having a transverse wall, a first side wall and a second side wall each extending from the transverse wall, the transverse wall defining a plurality of openings disposed spaced apart along a length of the transverse wall, the top rail further comprising a first locking ledge extending from the first side wall and a second locking ledge extending from the second side wall; 
 a plurality of picket plugs each comprising a pair of locking lugs in engagement with the first and second locking ledges of the top rail, each of the plurality of picket plugs having a picket-insertable portion configured to be aligned with one of the plurality of openings in the transverse wall of the top rail; and 
 a rail cap coupled to the top rail and concealing the plurality of picket plugs; 
   a plurality of pickets each configured to receive the picket-insertable portion of a respective one of the plurality of picket plugs; and   a bottom rail configured to couple to the plurality of pickets.   
     
     
         2 . The knockdown railing system of  claim 1  wherein at least one of the plurality of picket plugs defines a through hole configured to receive a fastener. 
     
     
         3 . The knockdown railing system of  claim 1  wherein at least one of the plurality of pickets comprises a threaded hole configured to receive a fastener. 
     
     
         4 . The knockdown railing system of  claim 3  wherein the fastener is received through one of the plurality of picket plugs. 
     
     
         5 . The knockdown railing system of  claim 1  wherein the pair of locking lugs are configured to engage the first and second locking ledges in a first orientation and configured to clear the first and second locking ledges in a second orientation. 
     
     
         6 . The knockdown railing system of  claim 5  wherein the pair of locking lugs are configured such that each picket plug can be rotated one-quarter turn from the first orientation to the second orientation. 
     
     
         7 . The knockdown railing system of  claim 1  wherein the picket-insertable portion of each of the picket plugs defines a channel. 
     
     
         8 . The knockdown railing system of  claim 7  wherein at least one of the plurality of pickets includes an inwardly extending wall configured to be received by the channel. 
     
     
         9 . The knockdown railing system of  claim 1  wherein at least one of the plurality of pickets includes a threaded member welded therein, the threaded member defining a threaded hole. 
     
     
         10 . The knockdown railing system of  claim 1  wherein the top rail, the bottom rail, and the plurality of pickets are each formed of aluminum. 
     
     
         11 . The knockdown railing system of  claim 1  wherein the top rail, the bottom rail, and the plurality of pickets are each formed by extruding a material. 
     
     
         12 . The knockdown railing system of  claim 1  wherein the top rail, the bottom rail, and the plurality of pickets are each formed by extruding a metal. 
     
     
         13 . The knockdown railing system of  claim 1  wherein the picket-insertable portion is received through the one of the plurality of openings. 
     
     
         14 . The knockdown railing system of  claim 1  wherein the picket-insertable portions and the plurality of openings are sized and shaped to form a clearance configured to receive a portion of each of the plurality of pickets. 
     
     
         15 . A knockdown railing system, comprising:
 a top rail assembly, comprising:
 a top rail having a top transverse wall, a first top side wall and a second top side wall each extending from the top transverse wall, the top transverse wall defining a plurality of top openings disposed spaced apart along a length of the top transverse wall, the top rail further comprising a first top locking ledge extending from the first top side wall and a second top locking ledge extending from the second top side wall; 
 a plurality of top picket plugs each comprising a pair of top locking lugs in engagement with the first and second top locking ledges and having a top picket-insertable portion configured to be aligned with one of the plurality of top openings in the top transverse wall; and 
 a rail cap coupled to the top rail and concealing the plurality of top picket plugs; 
   a bottom rail assembly, comprising:
 a bottom rail having a bottom transverse wall, a first bottom side wall and a second bottom side wall each extending from the bottom transverse wall, the bottom transverse wall defining a plurality of bottom openings disposed spaced apart along a length of the bottom transverse wall, the bottom rail further comprising a first bottom locking ledge extending from the first bottom side wall and a second locking ledge extending from the second bottom side wall; 
 a plurality of bottom picket plugs each comprising a pair of bottom locking lugs in engagement with the first and second bottom locking ledges and having a bottom picket-insertable portion configured to be aligned with one of the plurality of bottom openings in the bottom transverse wall; and 
   a plurality of pickets each configured to receive a respective one of the plurality of top picket-insertable portions in a top end and configured to receive a respective one of the plurality of bottom picket-insertable portions in a bottom end.   
     
     
         16 . The knockdown railing system of  claim 15  wherein at least one of the plurality of top picket plugs defines a through hole configured to receive a fastener. 
     
     
         17 . The knockdown railing system of  claim 15  wherein at least one of the plurality of pickets comprises a threaded hole configured to receive a fastener. 
     
     
         18 . The knockdown railing system of  claim 17  wherein the fastener is received through one of the plurality of top picket plugs. 
     
     
         19 . The knockdown railing system of  claim 1  wherein the pair of top locking lugs are configured to engage the first and second top locking ledges in a first orientation and configured to clear the first and second top locking ledges in a second orientation. 
     
     
         20 . A knockdown railing system, comprising:
 a top rail assembly, comprising:
 a top rail having a top transverse wall, a first top side wall and a second top side wall each extending from the top transverse wall, the top transverse wall defining a plurality of top openings disposed spaced apart along a length of the top transverse wall, the top rail further comprising a first top locking ledge extending from the first top side wall and a second top locking ledge extending from the second top side wall; 
 a plurality of top picket plugs each comprising a pair of top locking lugs in engagement with the first and second top locking ledges and having a top picket-insertable portion configured to be aligned with one of the plurality of top openings in the top transverse wall; and 
 a rail cap coupled to the top rail and concealing the plurality of top picket plugs; 
   a bottom rail assembly, comprising:
 a bottom rail having a bottom transverse wall, a first bottom side wall and a second bottom side wall each extending from the bottom transverse wall, the bottom transverse wall defining a plurality of bottom openings disposed spaced apart along a length of the bottom transverse wall, the bottom rail further comprising a first bottom locking ledge extending from the first bottom side wall and a second locking ledge extending from the second bottom side wall; 
 a plurality of bottom picket plugs each comprising a pair of bottom locking lugs in engagement with the first and second bottom locking ledges and having a bottom picket-insertable portion configured to be aligned with one of the plurality of bottom openings in the bottom transverse wall; and 
   a plurality of pickets each configured to receive a respective one of the plurality of top picket-insertable portions in a top end and configured to receive a respective one of the plurality of bottom picket-insertable portions in a bottom end;   wherein each of the top rail, bottom rail, and plurality of pickets are formed by extruding a metal.