Patent ID: 12247401

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure generally relates to a system and method of connecting balusters to a handrail. In embodiments, the disclosure includes a rail connector that connects (e.g., universally connects) a baluster (e.g., a hollow metal baluster or another suitable baluster) and a rail (e.g., a handrail for a stairway). In some embodiments, the rail connector can facilitate the installation of an angled rail system, such as those associated with stairs or ramps, a rail system having no angle, such as horizontal rails along balconies, stair landings, etc., and/or other suitable rail assemblies. The rail connector can be adaptable to be used with numerous different rail systems and angles.

FIGS.1-7illustrate an example embodiment of a connector1for connecting a baluster4to a rail5to form a rail and baluster assembly101(FIGS.3-6) including the connector1, and a method of forming the rail and baluster assembly101with the connector1in accordance with the disclosure. In one embodiment, the rail and baluster assembly101can include a handrail5and one or more balusters4mounted to the handrail5by the connector1(FIGS.3-7). In an exemplary embodiment, the rail5can be mounted between two support structures (e.g., newel posts, walls, etc.) (not shown) at an angle, extending along the rake of a set of stairs (FIGS.3-6), and/or level, extending horizontally along a floor (e.g., of a stair landing, a balcony, etc.) (FIG.7). In the illustrated embodiment, the rail5can be plowed/routed to form a plow or route21along its bottom, and the route21can include two sidewalls23(e.g., extending vertically along an interior of the route21) and a transverse face25(FIGS.3-7). In an exemplary embodiment, the route21can have a width of approximately ½-inch and a depth of approximately ¾-inch or could have any suitable dimensions. The rail5could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure.

As shown inFIGS.3-7, the baluster4can have a first or bottom end4a(e.g., a rounded or pin end) and a second or top end4b. In the illustrated embodiment, the bottom end4acan be a rounded or pin end (e.g., a cylinder or any suitable shape) and the top end4bcan be a square end (e.g., with a generally square cross-section or any suitable cross-sectional shape). At least the top end4bof the baluster4can be in the form of a tube (e.g., hollow) for at least partially receiving at least a portion of the connector1in the interior4cof the baluster4. In an exemplary embodiment, the entire length of the baluster4can be hollow. The baluster4could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure.

As shown inFIGS.1-2D, the connector1can include a first or lower section2and a second or upper section3. In the illustrated embodiment, the lower section2can include a lower shaft2a, which can have an octagonal cross-section or could have any suitable cross-sectional shape (e.g., a circle, an oval, a polygon, etc.). In exemplary embodiments, the shape of the lower shaft2acan at least partially correspond to the cross-sectional shape of the interior4cof the baluster4. As shown inFIGS.1and2B-2C, the lower shaft2acan include a plurality of wrapped ribs2b(e.g., interference fit ribs) extending around the perimeter of the lower shaft2aand spaced along the height of the lower section2. In the illustrated embodiment, the ribs2bcan be evenly spaced along the lower shaft2a, and each can have a triangular cross-section with a base that extends radially outwardly (e.g., horizontally) from the lower shaft2ato an outer edge of the rib2band a sloped surface extending downwardly and inwardly in an oblique direction from the outer edge to the lower shaft2a(e.g., the sloped surface extends inwardly and away from the upper section3as it extends from the outer edge of the rib2bto the lower shaft2a). In an exemplary embodiment, the ribs2bcan act as teeth gripping the inside wall of the baluster4by flexing the ribs2bin their range of motion when inserting the lower section2of the connector1into the top end4bof the baluster4. The ribs2bcan become compressed in the interior of the baluster4by the walls of the baluster when the lower section2of the connector1is inserted into the top end4bof the baluster4. The compression of the ribs2band/or frictional engagement of the ribs2bwith the interior of the baluster4can help resist removal of the connector1from the top end4bof the baluster4, opposing forces that may otherwise move the lower section2outwardly from the interior of the baluster4. In the illustrated embodiment, the ribs2bcan help create a tight and secure fit to the inside walls of the baluster4. Any portion of the lower section2, including at least the lower shaft2aand/or any of the ribs2b, could be omitted or could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure. For example, the ribs2bcould be unevenly spaced and/or could have any suitable cross-sectional shape.

As shown inFIGS.1-2D, the upper section3of the connector1can include a second or upper shaft3a, which can have a rectangular shape or any suitable shape. In the illustrated embodiment, oblique ribs3b(e.g., interference fit ribs) can extend outwardly from the upper shaft3a, can be evenly spaced along the upper shaft3a, and can have a triangular cross-section or any suitable cross-sectional shape. In one embodiment, the oblique ribs3bcan be at an inverse and oblique orientation with respect to the lower shaft ribs2band/or with respect to a central axis of the connector1(e.g., a central axis of the upper shaft3a). As shown inFIGS.1-2D, the upper shaft3acan include two sides31(e.g., a first side31and a second side31), a front face33, a rear face35, and a top face37. In the illustrated embodiment, the oblique ribs3bcan extend from the sides31between the front face33and the rear face35or the top face37. In embodiments, each of the oblique ribs3bcan have a base extending outwardly (e.g., perpendicularly to) the respective side31to an outer edge and a sloped surface extending inwardly and upwardly (e.g., away from the lower shaft2a) to the respective side31. In the illustrated embodiment, the oblique ribs3bcan be arranged so that the outer edges and the bases extend along a downward slope from the rear face35to the front face33.

In the illustrated embodiment, an oblique face3e(e.g., an angled notch) can extend from the front face33to the top face37along the same or a similar angle as the oblique ribs3b. For example, the angle of the oblique ribs3band the oblique face3ecan be approximately the average rake angle for a rail standard along a stair (e.g., an approximately 7⅜ slope). Alternatively, the oblique ribs3band/or the oblique face3ecan extend at any suitable angle for engaging a rail oriented at any suitable angle and/or the oblique ribs3band the oblique face3ecan extend at different angles. In the illustrated embodiment, the oblique ribs3bcan be angled to engage the sidewalls23of the route21so that the oblique ribs3bare compressed and/or deformed when inserting the upper section3of the connector1into the route21(e.g., while rotating the baluster4into position along a stair) so that the ribs3bresist motion away from the rail5, at least partially locking the baluster4into position. As shown inFIGS.1-2C, the oblique face3ecan be an additional guide for rotating the baluster4in position along a stair by engaging the transverse face25of the route21of the angled rail5(FIG.4) and helping to stop the baluster4from over rotating past vertical. Further, the top face37of the upper shaft3acan engage (e.g., contact, abut, etc.) the transverse face25of the route21for a horizontal rail5(FIG.7) to help position the baluster4during installation so that the connector1can be used for rake and level applications. In exemplary embodiments, the oblique face3ecan help maximize the number of oblique ribs3bpositioned along the sides31of the upper shaft3a.

As shown inFIGS.1-2D, a counterbored hole3dcan extend from the rear face35to the top face37and the oblique face3e(e.g., the hole3dcan be oriented perpendicularly to the oblique face3e). In the illustrated embodiment, the hole3dcan be adapted to receive a fastener8(FIGS.3-6) (e.g., a wood screw or other suitable fastener), to further fasten the baluster4to the underside of the rail5. While one hole3dis shown in the upper shaft3a, the connector1could include any suitable number of holes3dfor use with any suitable number of fasteners8or the hole3dand/or the fastener(s)8could be omitted. An opening or countersink41can be formed in the rear face35in communication with the hole3dfor accommodating the head of the fastener within the upper shaft3a. In exemplary embodiments, the mechanical attachment feature of the connector1can help accommodate or limit any bow that may exist in a section of the rail5.

As shown inFIGS.1and2B-2D, a baluster cap stop39(e.g., which can be a square shaft or can have any suitable shape) can act as a shoulder or ledge extending outwardly from the upper shaft3afor maintaining the depth of the connector1into the top end4bof the baluster4(e.g., so that the connector1is not inserted too far into the baluster4). Regardless of the quality of the finish cut of the baluster4, the cap stop39and the lower section2can help keep the connector1centered in the baluster4and seated at the highest cut point of the top end4bof the baluster4. In the illustrated embodiment, the connector1, nested and clamped inside of the baluster4with several rows of the ribs2bengaging the inside wall of the baluster4, can accommodate variations in the manufacturing of the baluster4(e.g., if the baluster finish cut is short, not straight, uneven, etc.) such as by adjusting how the connector1engages the top end4bof the baluster4(e.g., by not fully seating into the baluster4). In exemplary embodiments, the route21can at least partially conceal any imperfections in the top end4bof the baluster4when the upper section3is received in the route21, as described in more detail below, so that the addition of decorative shoes are not needed to hide the imperfections or variations in fit. Any portion of the upper section3, including at least the upper shaft3aany of the oblique ribs3b, the hole3d, the countersink41, the oblique face3e, the faces31,33,35,37, and/or the stop cap39, could be omitted or could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure. For example, the ribs3ccould be unevenly spaced.

Referring now toFIG.6, the rail connector1is shown with a baluster4, a plowed rail5, and tread6aof a stair. As shown inFIG.6, the rail5is positioned at an angle, along the rake of the stairs, and the rail5can be mounted to a support, such as a newel post or wall, at each end. In the illustrated embodiment, the lower section2of the connector1is inserted into the top end4bof the baluster4so that the ribs2bbecome deformed and compressed by the inner walls of the baluster4in its interior4cto help maintain the engagement between the connector1and the top end4bof the baluster4and resist removal of the lower section2of the connector from the interior4c. The connector1can be pressed into the top end4cuntil the cap stop39engages the top end4band resists further insertion of the connector1into the top end4b.

As shown inFIG.6, the treads6aof the stair can be drilled with one or more holes43(e.g., having a diameter of 7/16-inch or any suitable diameter) for receiving the pin end4aof respective balusters4. For example, each tread6acan include three holes. In the illustrated embodiment, the pin end4aof the baluster4can be positioned into one of the holes43in the tread6awith the connector1oriented so that the front face33and the oblique face3eare directed toward the rail5. Subsequently, the baluster4can be pivoted to a vertical orientation while pressing the upper section3of the connector1into the route21of the rail5. When the upper section3is inserted into the route21, the oblique face3ecan engage the transverse face25of the route21to stop further pivoting of the baluster1. As the upper section3is inserted into the route21, the side faces31of the upper shaft3acan be parallel to the sidewalls23of the route21so that the oblique ribs3bare deformed and compressed by the sidewalls23. Accordingly, the engagement of the oblique ribs3band the sidewalls23can help resist removal of the upper section3of the connector1from the route21and can help maintain the connection of the baluster4with the rail5via the connector1. In one embodiment, the interference fit between the oblique ribs3band the sidewalls23can help retain the oblique face3ein engagement with the transverse face25. In some embodiments, the connector1can be further secured to the rail5by inserting the fastener8into the hole3dvia the countersink41and screwing the fastener8into the rail5via the transverse face25of the route21(FIGS.3-6). In an example embodiment, a pilot hole can be drilled into the rail5before screwing the fastener8into place. In other embodiments, the fastener8could be omitted or any suitable number of fasteners could be used. This process can be repeated to connect balusters4to the rail5with the connectors1along the entire stairway from the first open tread at the bottom to the last open tread or along any suitable portion of the rail5.

As shown inFIGS.4and6, a fillet7can be inserted into the route21between each pair of connectors1along the length of the rail5. In the illustrated embodiment, the ends of the fillet7can be oblique so that they are in a vertical orientation when the fillet7extends along the angle of the rail5. Accordingly, the ends of the fillet7can engage the vertical rear face35of one connector1and the vertical front face33of the opposing connector1. In an exemplary embodiment, the fillets7can be secured with one or more fasteners (e.g., a pin nail or other suitable fastener) through the underside of the fillet7and/or the side of the rail5. Alternatively, or in addition, the fillets7can be secured with adhesive and/or other suitable features. In the illustrated embodiment, the fillet7can help retain the connectors1in position within the route21and can help conceal the connectors1and the route21on the underside of the rail5.

In one exemplary embodiment, the balusters4and the rail5can be assembled with the connectors1along the rake of a stair by plowing the underside of the top rail5to form the plow21(e.g., being ½-inch wide by ¾-inch deep or any suitable dimensions); setting appropriate number of newels or other supports (not shown) along the stairway; spacing and drilling the base holes43(e.g., having a diameter of 7/16-inch or any suitable diameter) evenly along each tread6a(e.g.,3holes per tread); setting the top rail5in between newels or other supports; selecting pre-cut balusters4for each position along the rake of the stair; inserting the lower section2of the connector1into the square top end4bof the respective balusters4; inserting the rounded end4aof each baluster4into the respective base holes43of the treads; pivoting the balusters4into the plow21of the rail5until balusters4are plumb; and inserting the fillet7in between the balusters4with a slight reveal along the bottom of the rail5.

Referring now toFIG.7, the rail connector1is shown with two balusters4, the rail5in a horizontal orientation, and floor6bhaving spaced holes43. In the illustrated embodiment, the pin end4aof the baluster4can be inserted into the holes43, which can be evenly spaced or could be otherwise spaced on the floor6b. The lower sections2of the connectors1can be inserted into the top ends4bof the balusters4as described above and the rail5can be lowered on top of the baluster4and secured by the rail connectors1similarly as described above for the sloped rail5. In one embodiment, the top face37of the upper shaft3aof the connector1can engage the traverse face25of the route21when the rail5is in position. In some embodiments, the fastener8can be installed as described above or could be omitted. Subsequently, the fillets7(e.g., have vertical ends) can be inserted between balusters4and secured with a pin nail or other suitable fastener through the underside of the fillet7and/or the side of the rail5. Alternatively, or in addition, the fillets7can be secured with adhesive and/or other suitable features.

In one exemplary embodiment, the balusters4and the rail5can be assembled with the connectors1in a level orientation of the rail5by plowing the underside of the top rail5to form the plow21(e.g., being ½-inch wide by ¾-inch deep or any suitable dimensions); setting appropriate number of newels or other supports (not shown) along the level rail5; spacing and drilling the base holes43(e.g., having a diameter of 7/16-inch or any suitable diameter) evenly along the floor6b(e.g., with a 4⅜″ center to center spacing); selecting the precut balusters4and inserting the pin end4aof each baluster4into the respective base holes43in the floor6b; inserting the lower sections2of the connectors1in the respective top ends4bof the respective balusters4; positioning the rail5on top of the balusters4with the upper sections3of the connectors1at least partially received in the route21; securing the rail5to the newels or other supports at a desired rail height; and inserting the fillets7between the balusters4with a slight reveal along the bottom of the rail5.

The handrail and baluster assembly101could be otherwise formed from the connector1, the baluster4, and the rail5without departing from the disclosure.

In embodiments, the connector1of the present disclosure can facilitate easier and faster installation of a balustrade. In some embodiments, the assembly can be entirely mechanical and the connector1can reduce or eliminate the need for adhesive/glue or epoxy, which can be messy. Also, since at least the connector1is concealed in the route21of the handrail5and by the fillets7, decorative shoes can be omitted if desired. In some embodiments, the rail5can be pre-prepared prior to onsite installation so that onsite measuring and drilling of the rail5can be avoided, while also allowing the opportunity to pre-finish the handrail5prior to installation.

In some embodiments, the route21in the rail5can allow the positioning of the balusters4at any point along the rail5so that the balusters4can be placed as needed without onsite drilling and measuring or with reduced onsite drilling and measuring. In addition, the route21of the rail5can provide two fixed faces23to which the connector1can wedge into. Further, the rail fillets7can be used to fill in between each baluster4once the balusters4are secured to the rail5(e.g., by the oblique ribs3band/or the fastener8). In some embodiments, the rail fillets7can add a secondary constraint to the balusters4, retaining the balusters4in the correct position while also filling the additional void in the bottom of the rail5.

Any of the features of the various embodiments of the disclosure can be combined with, replaced by, or otherwise configured with other features of other embodiments of the disclosure without departing from the scope of this disclosure.

The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.