Vertical cable barrier having rails with internal cable fitting engagement features

Abstract

A rail panel includes a first rail and a second rail. The first rail includes a first pair of side walls, a first perimeter wall disposed orthogonally to the first pair of side walls, a second perimeter wall disposed orthogonally to the first pair of side walls, and a pair of internal walls running parallel to and disposed spaced apart from the first pair of side walls. The first perimeter wall defines a plurality of first cable holes spaced apart along the length of the first perimeter wall. The second rail includes a second pair of side walls, and a third perimeter wall disposed orthogonally to the second pair of side walls. The third perimeter wall defines a plurality of second cable holes disposed spaced apart along the length of the third perimeter wall. A plurality of vertical cables extend from the first rail to the second rail, a first end of each of the plurality of vertical cables extend through a respective first cable hole, and a second end of each of the plurality of vertical cables extending through a respective second cable hole. At least one rigid support member is disposed among the plurality vertical cables and extends from the first rail to the second rail.

1 . A rail panel, comprising:
 a first rail comprising a first pair of side walls, a first perimeter wall disposed orthogonally to the first pair of side walls, a second perimeter wall disposed orthogonally to the first pair of side walls, and a pair of internal walls running parallel to and disposed spaced apart from the first pair of side walls, the first perimeter wall defining a plurality of first cable holes spaced apart along the length of the first perimeter wall;   a second rail comprising a second pair of side walls, and a third perimeter wall disposed orthogonally to the second pair of side walls, the third perimeter wall defining a plurality of second cable holes disposed spaced apart along the length of the third perimeter wall;   a plurality of vertical cables extending from the first rail to the second rail, a first end of each of the plurality of vertical cables extending through a respective first cable hole, and a second end of each of the plurality of vertical cables extending through a respective second cable hole; and   at least one rigid support member disposed among the plurality vertical cables and extending from the first rail to the second rail.   
     
     
         2 . The rail panel of  claim 1  further comprising a plurality of threaded members each coupled to a respective one of the plurality of vertical cables. 
     
     
         3 . The rail panel of  claim 2  wherein each of the plurality of threaded members and each of the plurality of first cable holes are sized to prevent a respective threaded member from passing through the associated first cable hole. 
     
     
         4 . The rail panel of  claim 2  wherein each of the plurality of threaded members comprises a flange portion configured to be received between the pair of internal walls of the first rail. 
     
     
         5 . The rail panel of  claim 1  further comprising a plurality of threaded fasteners each coupled to a respective one of the plurality of vertical cables, and wherein turning the threaded fastener adjusts a tension in the associated vertical cable. 
     
     
         6 . The rail panel of  claim 5  further comprising a cover configured to fit over the first rail and conceal the plurality of threaded fasteners. 
     
     
         7 . A rail panel, comprising:
 a first rail comprising a first pair of side walls, a first perimeter wall disposed orthogonally to the first pair of side walls, and a pair of internal walls extending from the first perimeter wall and disposed parallel to and spaced apart from the first pair of side walls, the first perimeter wall defining a plurality of first cable holes spaced apart along the length of the first perimeter wall;   a second rail comprising a second pair of side walls, and a second perimeter wall disposed orthogonally to the second pair of side walls, the second perimeter wall defining a plurality of second cable holes disposed spaced apart along the length of the second perimeter wall;   a plurality of vertical cables extending from the first rail to the second rail, a first end of each of the plurality of vertical cables extending through a respective first cable hole, and a second end of each of the plurality of vertical cables extending through a respective second cable hole; and   a rigid support member extending from the first rail to the second rail and disposed among the plurality of vertical cables.   
     
     
         8 . The rail panel of  claim 7  further comprising a plurality of threaded members, each coupled to a respective first end of one of the plurality of vertical cables. 
     
     
         9 . The rail panel of  claim 7  further comprising a plurality of angled inserts each seated within the first rail. 
     
     
         10 . The rail panel of  claim 9  wherein each of the plurality of angled inserts and each of the plurality of first cable holes are sized to prevent an angled insert from passing through a respective first cable hole. 
     
     
         11 . The rail panel of  claim 10  further comprising a plurality of threaded members, each coupled to a respective first end of one of the plurality of vertical cables, wherein each threaded member comprises a flange portion configured to be received by a respective angled insert. 
     
     
         12 . The rail panel of  claim 11  further comprising a plurality of threaded fasteners, each threaded to a respective threaded member, wherein turning the threaded fastener adjusts a tension in the associated vertical cable. 
     
     
         13 . The rail panel of  claim 12  further comprising a cover configured to fit over the first rail and conceal the plurality of threaded fasteners. 
     
     
         14 . A method of forming a rail panel, comprising:
 extruding a first rail, the first rail comprising a first pair of side walls, a first perimeter wall disposed orthogonally to the first pair of side walls, and a pair of internal walls extending from the first perimeter wall and disposed parallel to and spaced apart from the first pair of side walls;   forming a plurality of first cable holes spaced apart along the length of the first perimeter wall;   extruding a second rail, the second rail comprising a second pair of side walls, and a second perimeter wall disposed orthogonally to the second pair of side walls;   forming a plurality of second cable holes disposed spaced apart along the length of the second perimeter wall;   assembling a rigid support member to the first and second rails; and   assembling a plurality of vertical cables to the first and second rails, comprising applying a plurality of clips to a plurality of clip receiving swage fittings and tightening a plurality of threaded fasteners to tension the plurality of vertical cables.   
     
     
         15 . The method of  claim 14 , wherein at least a portion of each of the plurality of clip receiving swage fittings is received by a respective one of the plurality of second cable holes. 
     
     
         16 . The method of  claim 14  wherein assembling the rigid support member comprises securing the rigid support member to the first rail using a fastener. 
     
     
         17 . The method of  claim 14  wherein assembling the plurality of vertical cables comprises swaging a threaded fitting to an end of each of the plurality of vertical cables. 
     
     
         18 . The method of  claim 17  wherein assembling the plurality of vertical cables to the first and second rails comprises rotating a respective one of the plurality of threaded fasteners onto the threaded fittings. 
     
     
         19 . The method of  claim 14  further comprising applying a cover over the first rail to conceal the plurality of threaded fasteners. 
     
     
         20 . The method of  claim 14  further comprising tensioning each of the plurality of vertical cable to a predetermined tension.