Composite spindle

#The present invention is directed to decking and fencing products, and in particular to spindles and balusters for decking and fencing.

#Outdoor decks and fences are extremely popular in residential home construction. Homes and apartments, as well as a variety of other buildings, often incorporate exterior decks and fences into their design. Additionally, decks and fences are commonly added onto existing structures and landscapes. These decks and fences provide convenient spaces for a variety of outdoor activities, including cookouts, dining and sunbathing, as well as other leisure activities. Moreover, decks typically are provided with a railing or perimeter fence to keep people from falling over the edge of the deck.

#Wood products have traditionally been the primary source of materials for use in decking construction. However, wood products are becoming increasingly scarce due to the harvesting of trees at ever faster rates and the rather limited rate at which timber resources can be replenished. Also, environmental concerns and regulations directed to conservation or preservation of forests tend to restrict the availability of wood products. With the diminishing availability of timber resources, wood products are becoming increasingly expensive. There is, therefore, a substantial need for long lasting substitute construction materials that can lessen the need to harvest timber resources.

#FIG. 1 is a perspective illustration of a spindle or baluster according to a preferred form of the invention.

#FIG. 2 is a sectional illustration of the spindle or baluster of FIG. 1.

#FIG. 3A is a partially cut-away illustration of a portion of the spindle or baluster of FIG. 1.

#Referring now to the drawing figures, wherein like reference numerals depict like parts throughout the several views, FIGS. 1 and 2 show a composite spindle 10 according to a preferred form of the invention. The composite spindle 10 generally comprises a rigid plastic outer shell 11, a steel tubular reinforcing element 12, and high density polyurethane foam 13 and 14 for securing the steel tubular reinforcing element 12 within the PVC outer shell 11.

#The PVC outer shell 11 includes a first end section 16, a second end section 17 opposite the first end section 16, and an intermediate section 18 between the first and second end sections. Each of the end sections 16, 17 is square in cross-section over substantially their entire lengths, with a transition region 22, 23 easing the transition between the square cross-section of the end sections 16, 17 and the "turned" profile of the intermediate section 18. In this regard, the overall visual effect of the spindle is that of a traditional, wooden spindle which, while initially square in cross-section along its entire length, is formed by turning it on a lathe to produce the rounded shapes in the intermediate section, such as the rounded shapes depicted in FIGS. 1 and 2.

#For illustration purposes, FIGS. 1 and 2 depict an intermediate section having certain design elements common to turned wooden posts or spindles. For example, as depicted in FIGS. 1 and 2, the intermediate section includes three bulbous transition elements 26, 27 and 28. A pair of club shaped or bat shaped surfaces 31 and 32 extend between the bulbous transition elements 26 and 27 and 27 and 28, respectively. Of course, other shapes are possible.