Patent Publication Number: US-2020277793-A1

Title: Baluster Shoes

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a Non-Provisional patent application and claims priority to U.S. Provisional Patent Application Ser. No. 62/811,678, filed Feb. 28, 2019, which is incorporated by reference herein. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to shoes for balusters, and in some aspects relates to adjustable baluster shoes. 
     BACKGROUND 
     Handrails, safety railings and the like are often supported by a number of spaced-apart vertical members often called balusters. Balusters may be uniformly square or rounded in cross-section along their lengths, may vary in cross-section along their lengths, and/or may include decorative elements that differ from other more linear portions along their lengths. Balusters may be made of wood, metal, stone, plastic, etc., or combinations of materials. 
     Balusters are attached at a bottom end to a mounting surface, which could be a horizontal or angled relative to horizontal footing, stair step, floor surface or other surface. Balusters are attached at a top end to a mounting surface such as a handrail, railing, etc., which again may be horizontal or angled relative to horizontal. 
     Often “shoes” that surround a baluster are used to cover imperfections, mounting holes, etc., and/or add decorative appeal to the point of connection between the ends of the balusters and the top or bottom mounting surfaces. However, existing shoes that are single pieces cannot be attached after installation of a baluster. Also, many balusters are made with ends in standard sizes for modular use in the building and renovation industry (e.g., 0.25, 0.375, 0.5, 0.75, 1.0, 1.25 inch, etc., squares or diameters, or similar ranges of metric sizing). If sizing of the shoes (i.e., the openings for receiving the balusters) is closely selected to match the sizing of the balusters, and if balusters are installed with slight variation to desired orientation (i.e., skewed slightly from vertical), the shoes may not sit with bottom surfaces aligned with the mounting surface producing gaps between the baluster shoe and the mounting surface and or the baluster. Such gaps can sometimes be produced in baluster shoes secured to balusters by set screws, where tightening of the set screw causes such a misalignment of the shoe relative to the surface(s) adjacent the baluster end(s). 
     Accordingly, a baluster shoe that addresses one or more drawbacks of existing baluster shoes or one or more of the above issues, that is readily manufactured and installed, that is cost effective, and/or that addresses any other issues would be welcome. 
     SUMMARY 
     According to certain aspects of the disclosure, an adjustable shoe is disclosed for a baluster attached to a mounting surface and having a longitudinal axis and cross-section of a predetermined size, the adjustable shoe including, for example, a first part having a body with an inner surface, an outer surface, a top surface, and a bottom surface; and a second part having a body with an inner surface, and outer surface a top surface and a bottom surface. The second part is attachable to first part to define an opening between the at least a portion of the inner surfaces of the first part and the second part, the opening defining a central axis and being configured for receiving the baluster therethrough. The opening is configured so that the first part and the second part may be adjustably attached to the baluster with the central axis and the longitudinal axis at an angle of up to about 10 degrees to compensate for any misalignment of the baluster and the mounting surface. Various options and modifications are possible. 
     For example, at least a portion of the inner surfaces of the first part and the second part include a wall parallel to the central axis. If so, the wall may include four walls arranged so that a cross-section perpendicular to the central axis is a square, or the wall may be annular. The angle between the central axis and the longitudinal axis may be about 8 degrees. 
     At least a portion of the inner surfaces of the first and second parts may include a wall non-aligned with the central axis so as to form a frustum. If so, the wall may include four walls arranged so that a cross-section perpendicular to the central axis is a square, or the wall may be annular. The angle between the central axis and the longitudinal axis of such wall may be about 8 degrees, and the angle between the central axis and the wall may be about 8 degrees. 
     If the shoe includes four walls, three of the walls may be on the first part and a fourth of the walls being on the second part. The first and second parts may be removably attachable to each other. The first and second parts may have cooperating tabs and slots for removable attachment via sliding in a direction along the central axis. The first part may include three detachable sections, each of the detachable sections and the second part encompassing about one quarter of the opening, and the three detachable sections and the second part may all be substantially identical. 
     The shoe may further include a cap attachable to the top surfaces of the first part and the second part. The top surfaces may define a recess for receiving the cap in a snap fit, and the cap may define an opening sized for receipt of the baluster therethrough, and the cap may include two sections. Also, the cap may be formed of a resiliently deformable material. The cap on one hand and the first part and the second part on the other hand may be sized for frictional engagement wherein upon assembly the cap is secured to the first part and the second part thereby and the first part and the second part are secured to the baluster thereby. 
     The bottom surfaces of the first and second parts may include portions substantially perpendicular to the central axis and configured for use with a substantially horizontal mounting surface, or may include portions at an angle relative to the central axis and configured for use with a substantially non-horizontal mounting surface. 
     An adhesive may be located on at least one of the bottom surfaces of the first part and the second part for securing the first part and the second part to the mounting surface. 
     The adjustable shoe may include only one of the first parts and only one of the second parts, the only one first part and the only one second part each extending about 180 degrees around the central axis. If so, the only one first part and the only one second part may be identical, and/or the only one first part and the only one second part may be generally L-shaped when viewed along a line parallel to the central axis. 
     An assembly may be created including the adjustable shoe and the baluster. The baluster may have a cross-section perpendicular to the longitudinal axis, wherein the cross-section is rectangular, square, or circular. 
     According to other aspects of the disclosure, an adjustable shoe is disclosed for a baluster attached to a mounting surface and having a longitudinal axis and cross-section of a predetermined size, the adjustable shoe includes, for example, a first part having a body with an inner surface, an outer surface, a top surface, and a bottom surface, and a second part having a body with an inner surface, and outer surface a top surface and a bottom surface. The second part is attachable to first part to define an opening between the at least a portion of the inner surfaces of the first part and the second part, the opening defining a central axis and being configured for receiving the baluster therethrough. The opening is configured so that the first part and the second part may be adjustably attached to the baluster with the central axis pivotable relative to the longitudinal axis to compensate for any misalignment of the baluster and the mounting surface. A cap is attached to the top surfaces of the first part and the second part and around the baluster. The cap defines an opening sized for receipt of the baluster therethrough. The cap is formed of a resiliently deformable material softer than the first part, the second part, and the baluster so that the cap secures the first part and the second part to the baluster. Various options and modifications are possible. 
     For example, the top surfaces of the first part and the second part may define a recess for receiving the cap in a snap fit. The cap may include two sections, or may include a radially extending slit from the opening to an outer edge. The first part and the second part may be configured so that the central axis is pivotable relative to the longitudinal axis by up to about 10 degrees. An adhesive may be located on at least one of the bottom surfaces of the first part and the second part for securing the first part and the second part to the mounting surface. 
     The adjustable shoe may include only one of the first parts and only one of the second parts, the only one first part and the only one second part each extending about 180 degrees around the central axis. If so, the only one first part and the only one second part may be identical, and/or the only one first part and the only one second part may be generally L-shaped when viewed along a line parallel to the central axis 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a close-up perspective view of a six-part baluster shoe installed along an adjacent horizontal lower mounting surface. 
         FIG. 2  is an exploded perspective view of the baluster shoe as in  FIG. 1 . 
         FIG. 3  is a side view of baluster shoes placed at tops and bottoms of balusters installed along horizontal upper and lower mounting surfaces. 
         FIG. 4  is a side view of baluster shoes placed at tops and bottoms of balusters installed along non-horizontal upper and lower mounting surfaces. 
         FIG. 5  is an exaggerated diagrammatical sectional view showing adjustability of the baluster shoe as in  FIG. 1  relative to the baluster and/or mounting surface. 
         FIG. 6  is an exaggerated diagrammatical sectional view as in  FIG. 5 , with an alternate baluster configuration. 
         FIG. 7  is a close-up perspective view of a modified four-part baluster shoe installed along an adjacent horizontal lower mounting surface. 
         FIG. 8  is an exploded perspective view of the baluster shoe as in  FIG. 7 . 
         FIG. 9  is a close-up perspective view of another modified four-part baluster shoe installed along an adjacent non-horizontal lower mounting surface. 
     
    
    
     DETAILED DESCRIPTION 
     Detailed reference will now be made to the drawings in which examples embodying the present disclosure are shown. The detailed description uses numeral and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the disclosure. 
     The drawings and detailed description provide a full and enabling description of the disclosure and the manner and process of making and using it. Each embodiment is provided by way of explanation of the subject matter not limitation thereof. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made to the disclosed subject matter without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment may be used with another embodiment to yield a still further embodiment. 
     Generally speaking, the Figures depict several examples of adjustable shoes for a baluster and attachable to a mounting surface (either upper or lower). The adjustable shoes are made of more than one part and can be assembled around the baluster after installation of the baluster, and thus need not be placed on (i.e., slid onto) the baluster before the baluster is secured to the mounting surfaces. The shoes are adjustable within a range allowing for secure, decorative placement that takes into account minor misalignment between the baluster and mounting surface (upper or lower) to which the baluster is connected. The adjustable shoes can be configured to be mounted adjacent horizontal surfaces or sloped surfaces, at upper or lower ends of balusters. A flexible, resilient, and/or frictional fit of some sort, and/or an adhesive, may be used to hold the adjustable shoe in place adjacent the mounting surface. 
     As shown, baluster shoe  20  of  FIGS. 1 and 2  includes multiple (four) parts  22 ,  24 ,  26 , and  28  that surround baluster  30  for placement adjacent mounting surface  32 . Baluster  30  has a central longitudinal axis  31  therethrough adjacent mounting surface  32  where shoe  20  will be located. 
     Mounting surface  32  as shown is horizontal and is a lower surface, but it could be an upper surface and/or non-horizontal as well. Thus, as shown in  FIG. 3 , baluster shoes  20  may be installed in locations as follows: shoes  20   a  for mounting on a bottom horizontal surface  32   a  or shoes  20   b  for mounting on a top horizontal surface  32   b .  FIG. 4  shows alternate shoe designs (discussed in more detail below), with shoes  20   c  and  20   d  respectively mounted to bottom and top non-horizontal (angled) mounting surfaces  32   c  and  32   d.    
     As shown, the four parts  22 - 28  each extend about ¼ of the way (about 90 degrees circumferentially) around baluster  30 , with structures for interlocking with adjacent parts to form a completed shoe. As illustrated as and will be described in more detail below, the ends of parts  22 - 28  meet and interlock roughly at circumferential corners of the resulting generally square baluster shoe  20  around a generally square portion of baluster  30 , although the interlock locations may be elsewhere around the circumference. Also, baluster shoe  20  once assembled need not be generally externally square. For example, baluster shoe  20  could be externally curved, circular, irregularly shaped, etc., in any desired fashion for functional covering of the baluster/mounting surface interface and/or design appearance. 
     It should be understood that in a broad sense, the invention requires only two such shoe parts. Thus, one part may be as illustrated and extend about ¼ of the way (about 90 degrees) around baluster  30 , and the other part may modified to be a unitary part extending ¾ of the way (about 270 degrees) around, in a generally “U” shaped configuration. In other words, part  22  could remain as shown, and parts  24 - 28  could be combined into one U-shaped part. 
     Alternatively, parts  22  and  24  could be formed unitarily and parts  26  and  28  could be formed unitarily. The resulting to two parts would thus both extend about ½ of the way (about 180 degrees) around baluster  30  in a generally “L” shaped configuration. The resulting two parts ( 22 + 24  and  26 + 28 ) could be symmetrical and thus identical, thereby providing manufacturing, supply, and inventory efficiencies. As above, the resulting parts of such a modified shoe could be made to have differing exterior shapes for functional and/or design reasons. Other amounts of parts greater than two could be used (i.e., three) if desired for square or round balusters. 
     As illustrated (see  FIGS. 1, 2, and 5 ), each part  22 - 28  has a body with an inner surface  34 , an outer surface  36 , a top surface  38 , and a bottom surface  40 . Therefore, the at least two parts of shoe  20  are attachable together to define an opening  42  between the at least a portion of the inner surfaces  34  of the parts  22 - 28 . Opening  42  defines a central axis  44 . Opening  42  is sized and configured for receiving baluster  30  for placement near mounting surface  32 . Note that in  FIG. 5 , the slant of baluster  30  relative to surface  32  is exaggerated, and the width of baluster  30  is reduced compared to the width of opening  42  for illustrative purposes, as noted below. 
     Opening  42  is sized and configured to allow for some degree of adjustability of baluster shoe  20  relative to baluster  30  and/or mounting surface  32  to account for any potential imperfection or misalignment that may be present. For example, it may be desired to allow parts  22 - 28  to pivot relative to baluster  30  by an angle a of up to 10 about degrees, or more particularly about 8 degrees. Such ranges generally account for commercially acceptable minor misalignment, as opposed to for example, poor or substandard installation. Again, angle a as illustrated is substantially greater than 10 degrees, for purposes of clearer illustration of disclosed adjustability concepts. Such degree of pivot could be achieved in multiple ways. 
     First, parts  22 - 28  can be configured so that opening  42  is sized lightly larger than baluster  30  so that a relative pivoting of up to about 10 degrees, or about 8 degrees is possible. Inner surfaces  34  of parts  22 - 28  can be made with contact portions  46  that are generally parallel to each other and desirably to sides  48  of baluster  30  if installed perpendicularly to mounting surface  32 . Such holds true whether the cross-section of baluster  30  and opening  42  is square, angular, curved, round, etc. 
     Alternatively or additionally, as shown in similarly exaggerated  FIG. 6 , parts  22 - 28  can be configured so that inner surfaces  34   a  have contact portions  46   a  that are not substantially parallel to each other. Thus, contact portions  46   a  may flare outward in a direction (downward as shown) toward mounting surface  32 , for example in a frustum shape. Again, such structure can be employed regardless of the cross-sectional shape of baluster  30  and opening  42   a.    
     To facilitate assembly of parts  22 - 28  around baluster  30 , each part may have connecting elements, such as a cooperating tab  50  and/or slot  52 . As shown,  50  tabs are provided on parts  22  and  26  and slots  52  slots are provided on parts  24  and  28  to allow for assembly via sliding and/or a snap fit in a direction generally along central axis  44 . However, each of parts could have one tab and one slot if desired, so that instead of two types of parts only one type is required. Also, sliding and/or a snap fit in a direction perpendicular to central axis  44  is also possible. Again, two or more of such parts  22 - 28  (i.e., four identical parts, two identical L shapes, two identical U shapes, or two non-identical parts: one being a U shape, etc.) may be employed in shoe  20  with corresponding placement of such connecting elements. 
     If desired, a cap  54  may be provided attachable to top surfaces  38  of parts  22 - 28 , and such cap may fit into a recess  56  in such top surfaces. Cap  54  may be made of a hard plastic or elastomer that is resiliently deformable. Cap  54  may comprise two parts  54   a , 54   b  as shown, or a single part with a slit which can be useful for attaching to balusters already in place. Cap  54  provides a cosmetic cover covering seams between parts  22 - 28  and the interface with baluster  30 . 
     Cap  54  may also at least assist in securing parts  22 - 28  in place on baluster  30  adjacent mounting surface  32 . Cap  54  may define a central opening  55  sized for snugly fitting around baluster  30  when cap is placed into recess  56 . Thus, use of cap  54  to secure shoe  20  in place can eliminate the need for tools or a conventional set screw to hold shoe  20  in place, wherein a set screw might undesirably align shoe  20  with baluster  30  but not mounting surface  32 . If cap  54  is used for decorative and/or securement purposes, it should therefore be configured to permit the relative adjustment of shoe  20  relative to baluster  30  up to about 10 degrees noted above. Such securement can be used on top and bottom baluster shoes  20   a  and  20   b.    
     The securement can also or alternatively be provided by an adhesive  58  located between at least one bottom surface  40  and the corresponding mounting surface  32 . The adhesive may be supplied separately (i.e., squeezed from a tube or the like), or may be incorporated and placed onto shoe  20  during manufacture or assembly (i.e., in the form of an adhesive or double-sided adhesive tape covered by a release paper). Again, use of an adhesive allows connection of shoe  20  to baluster  30  flush with mounting surface  32  without use of a set screw that might interfere with the desired alignment. Use of adhesive and an elastomeric cap can assist with placement, alignment, securement, and visual appeal, although both are not required in all aspects. 
       FIGS. 7 and 8  show an alternate embodiment of a shoe  120  having two u-shaped parts  122  and  124  and cap  154  (parts  154   a  and  154   b  and opening  155 ). Tabs  150  fit in slots  152  to hold shoe parts  122  and  124  together, similar as to above. Each surfaces  146  on parts  122  and  124  may extend along three sides of the resulting opening  142  to potentially contact three sides of baluster  30  when assembled thereon. The embodiment of  FIGS. 7 and 8  shows that edges between parts need not be at corners of the shoe (if square), but could instead be between the corners. 
       FIG. 9  show another alternate embodiment of a shoe  220  having four parts  222 ,  224 ,  226 ,  228 , and a cap  254 . Shoe is essentially similar to shoe  20 , except the bottom edges  242 ,  244 , and  246  of parts  222 ,  224 , and  226  are modified so that shoe  220  can be used on a non-horizontal surface  232  (such as  32   c  or  32   d  in  FIG. 4 ). 
     While one or more preferred embodiments have been described above, it is to be understood that any and all equivalent realizations of the disclosed subject matter are included within the scope and spirit thereof. Thus, the embodiments depicted are presented by way of example only and are not intended as limitations upon the present invention. Thus, while particular embodiments have been described and shown, it will be understood by those of ordinary skill in this art that the present invention is not limited thereto since many modifications can be made. Therefore, it is contemplated that any and all such embodiments are included in the present invention as may fall within the literal or equivalent scope of the appended claims.