Baluster Installation System and Method
20220243476 · 2022-08-04
Inventors
Cpc classification
E04F11/1846
FIXED CONSTRUCTIONS
International classification
Abstract
A baluster installation system. The system can comprise a connector comprising a first section for engaging an end of a baluster and a second end for engaging a route in a handrail. The first section can comprise a first shaft and a plurality of first ribs extending from the first shaft, and the second section can include a second shaft and a plurality of second ribs extending from the second shaft. The first ribs can be adapted to engage a portion of the baluster when the first section is engaged with the end of the baluster, and the second ribs can be adapted to engage sidewalls of the route when the second section is engaged with the route.
Claims
1. A baluster installation system comprising a connector, comprising: a first section for being at least partially received in an end of a baluster, the first section comprising a first shaft and a plurality of first ribs extending from the first shaft, wherein the plurality of first ribs is adapted to engage a portion of the baluster when the first section is at least partially received in the end of the baluster; and a second section for being at least partially received in a route in a handrail, the second section comprising a second shaft and a plurality of second ribs extending from the second shaft, wherein the plurality of second ribs is adapted to engage sidewalls of the route when the second section is at least partially received in the route.
2. The baluster installation system of claim 1, wherein each first rib of the plurality of first ribs comprises a wrapped rib extending around a perimeter of the first shaft, and the first ribs are spaced along a height of the first shaft.
3. The baluster installation system of claim 1, wherein each first rib of the plurality of first ribs comprises a base that extends radially outwardly from the first shaft.
4. The baluster installation system of claim 3, wherein each of the first ribs has a triangular cross-section with a sloped surface extending from the base to the first shaft and away from the second section.
5. The baluster installation system of claim 1, wherein the second shaft comprises at least a side extending between at least two faces of the second shaft, and second ribs of the plurality of second ribs are spaced along the side.
6. The baluster installation system of claim 1, wherein the second shaft comprises a first side and a second side, each extending from a front face to a rear face of the second shaft, and each second rib of the plurality of second ribs extends on one of the first side and the second side.
7. The baluster installation system of claim 1, wherein each second rib of the plurality of second ribs has a triangular cross-section and extends obliquely with respect to the plurality of first ribs.
8. The baluster installation system of claim 1, wherein the second shaft comprises at least a front face, a top face, and an oblique face extending between the top face and the front face, and each second rib of the plurality of second ribs is parallel to the oblique face.
9. The baluster installation system of claim 8, wherein the second shaft comprises a rear face opposite to the front face and defines a hole extending from the rear face to the top face and the oblique face, the hole extends perpendicular to the oblique face, and the hole is adapted to at least partially receive a fastener for at least partially securing the connector to the handrail.
10. A method of attaching a baluster to a handrail, the method comprising: obtaining a connector comprising a first section with a first shaft and a plurality of first ribs extending from the first shaft and a second section with a second shaft and a plurality of second ribs extending from the second shaft; engaging the first section of the connector with an end of a baluster; and engaging the second section of the connector with a route formed in a handrail.
11. The method of claim 10, wherein the plurality of first ribs is in frictional engagement with the end of the baluster after the engaging the first end of the connector with the end of the baluster, and the plurality of second ribs is in frictional engagement with sidewalls of the route of the handrail after the engaging the second section of the connector with the route.
12. The method of claim 10, wherein the second shaft comprises at least a top face and an oblique face, the handrail has a transverse face extending along the route, and the engaging the second section of the connector with the route comprises positioning the second section in the route so that the transverse face of the route abuts at least one of the top face and the oblique face of the second shaft.
13. The method of claim 10, further comprising positioning the handrail to extend along a rake of a stair, wherein the second shaft of the connector comprises an oblique face, and the engaging the second section of the connector with the route comprises positioning the second shaft within the route so that the oblique face abuts a face of the handrail extending in the route along the rake of the stair.
14. The method of claim 10, further comprising securing the connector to the handrail by securing a fastener to the handrail via a hole defined in the second shaft and into a face of the handrail extending along the route.
15. The method of claim 10, further comprising inserting a fillet into the route proximate the connector after the engaging the second section of the connector with the route.
16. A handrail and baluster assembly, comprising: a handrail defining a route; a baluster having an end extending at least partially around an interior of the baluster; and a connector comprising: a first section at least partially received in the interior at the end of the baluster, the first section comprising a first shaft and a plurality of first ribs extending from the first shaft, wherein the plurality of first ribs engages a portion of the baluster in the interior of the baluster for at least partially retaining the first section in the interior of the end of the baluster; and a second section at least partially received in the route in the handrail, the second section comprising a second shaft and a plurality of second ribs extending from the second shaft, wherein the plurality of second ribs engages sidewalls of the route for at least partially retaining the second section in the route.
17. The handrail and baluster assembly of claim 16, wherein the plurality of first ribs is in frictional engagement with a wall of the baluster extending along the interior of the end of the baluster, and the plurality of second ribs is in frictional engagement with the sidewalls of the route of the handrail.
18. The handrail and baluster assembly of claim 16, wherein the second shaft comprises at least a top face and an oblique face, the handrail has a transverse face extending between the sidewalls of the route, and the transverse face of the route abuts at least one of the top face and the oblique face of the second shaft.
19. The handrail and baluster assembly of claim 16, wherein the second shaft comprises an oblique face engaging a transverse face of the route of the handrail, and the oblique face of the second shaft and the transverse face of the route extend along a similar or identical angle as a rake of a stair.
20. The handrail and baluster assembly of claim 16, wherein the second shaft comprises a rear face, an oblique face, a top face extending from the rear face to the oblique face, and a hole extending at least partially perpendicularly with respect to the oblique face from the rear face to the top face and the oblique face, and the connector is at least partially secured to the handrail by a fastener at least partially received in the hole and extending into the handrail via the route.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.
[0016]
[0017]
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[0020]
[0021]
[0022]
[0023] Corresponding parts are designated by corresponding reference numbers throughout the drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0024] 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.
[0025]
[0026] As shown in
[0027] As shown in
[0028] As shown in
[0029] In the illustrated embodiment, an oblique face 3e (e.g., an angled notch) can extend from the front face 33 to the top face 37 along the same or a similar angle as the oblique ribs 3b. For example, the angle of the oblique ribs 3b and the oblique face 3e can be approximately the average rake angle for a rail standard along a stair (e.g., an approximately 7⅜ slope). Alternatively, the oblique ribs 3b and/or the oblique face 3e can extend at any suitable angle for engaging a rail oriented at any suitable angle and/or the oblique ribs 3b and the oblique face 3e can extend at different angles. In the illustrated embodiment, the oblique ribs 3b can be angled to engage the sidewalls 23 of the route 21 so that the oblique ribs 3b are compressed and/or deformed when inserting the upper section 3 of the connector 1 into the route 21 (e.g., while rotating the baluster 4 into position along a stair) so that the ribs 3b resist motion away from the rail 5, at least partially locking the baluster 4 into position. As shown in
[0030] As shown in
[0031] As shown in
[0032] Referring now to
[0033] As shown in
[0034] As shown in
[0035] In one exemplary embodiment, the balusters 4 and the rail 5 can be assembled with the connectors 1 along the rake of a stair by plowing the underside of the top rail 5 to form the plow 21 (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 holes 43 (e.g., having a diameter of 7/16-inch or any suitable diameter) evenly along each tread 6a (e.g., 3 holes per tread); setting the top rail 5 in between newels or other supports; selecting pre-cut balusters 4 for each position along the rake of the stair; inserting the lower section 2 of the connector 1 into the square top end 4b of the respective balusters 4; inserting the rounded end 4a of each baluster 4 into the respective base holes 43 of the treads; pivoting the balusters 4 into the plow 21 of the rail 5 until balusters 4 are plumb; and inserting the fillet 7 in between the balusters 4 with a slight reveal along the bottom of the rail 5.
[0036] Referring now to
[0037] In one exemplary embodiment, the balusters 4 and the rail 5 can be assembled with the connectors 1 in a level orientation of the rail 5 by plowing the underside of the top rail 5 to form the plow 21 (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 rail 5; spacing and drilling the base holes 43 (e.g., having a diameter of 7/16-inch or any suitable diameter) evenly along the floor 6b (e.g., with a 4⅜″ center to center spacing); selecting the precut balusters 4 and inserting the pin end 4a of each baluster 4 into the respective base holes 43 in the floor 6b; inserting the lower sections 2 of the connectors 1 in the respective top ends 4b of the respective balusters 4; positioning the rail 5 on top of the balusters 4 with the upper sections 3 of the connectors 1 at least partially received in the route 21; securing the rail 5 to the newels or other supports at a desired rail height; and inserting the fillets 7 between the balusters 4 with a slight reveal along the bottom of the rail 5.
[0038] The handrail and baluster assembly 101 could be otherwise formed from the connector 1, the baluster 4, and the rail 5 without departing from the disclosure.
[0039] In embodiments, the connector 1 of the present disclosure can facilitate easier and faster installation of a balustrade. In some embodiments, the assembly can be entirely mechanical and the connector 1 can reduce or eliminate the need for adhesive/glue or epoxy, which can be messy. Also, since at least the connector 1 is concealed in the route 21 of the handrail 5 and by the fillets 7, decorative shoes can be omitted if desired. In some embodiments, the rail 5 can be pre-prepared prior to onsite installation so that onsite measuring and drilling of the rail 5 can be avoided, while also allowing the opportunity to pre-finish the handrail 5 prior to installation.
[0040] In some embodiments, the route 21 in the rail 5 can allow the positioning of the balusters 4 at any point along the rail 5 so that the balusters 4 can be placed as needed without onsite drilling and measuring or with reduced onsite drilling and measuring. In addition, the route 21 of the rail 5 can provide two fixed faces 23 to which the connector 1 can wedge into. Further, the rail fillets 7 can be used to fill in between each baluster 4 once the balusters 4 are secured to the rail 5 (e.g., by the oblique ribs 3b and/or the fastener 8). In some embodiments, the rail fillets 7 can add a secondary constraint to the balusters 4, retaining the balusters 4 in the correct position while also filling the additional void in the bottom of the rail 5.
[0041] 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.
[0042] 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.