BALUSTER ATTACHMENT SYSTEM

Abstract

A baluster mount system includes a fastener, a fixed element and a pivot element. The fastener attaches the fixed element to the stairway substrate. The fixed element has a substrate portion and an attachment portion, and the attachment portion includes one of a clevis and a tang. The pivot element has a tubular portion and a secondary attachment portion. The secondary attachment portion includes the other of the clevis and the tang. A pin extends through the attachment portion and the secondary attachment portion to pivotally connect the fixed element and the pivot element. An end portion of the baluster is inserted into the tubular portion of the pivot element, and the baluster end may be retained in the tubular portion by a set screw extending into the tubular portion.

Claims

1. A system for attaching a baluster to a stairway substrate, comprising: a screw having a first threaded end and a second threaded end opposite the first end, the first end threaded into the stairway substrate to secure the screw to the substrate; a fixed element having a substrate portion and an attachment portion, the substrate portion threaded onto the second end of the screw, the attachment portion including one of a clevis and a tang extending from the substrate portion; a pivot element having a tubular portion and a secondary attachment portion, the tubular portion including a sidewall defining an open end, the secondary attachment portion including the other of the clevis and the tang; and a pin extending through the attachment portion and the secondary attachment portion to connect the fixed element and the pivot element.

2. The system of claim 1 including a baluster having an end portion inserted into the open end of the tubular portion of the pivot element, the baluster end portion retained in the tubular portion by a set screw extending through the sidewall of the tubular portion and engaging the baluster.

3. The system of claim 2 wherein the attachment portion is the clevis and the secondary attachment portion is the tang, the tang inserted into the clevis, and the pin inserted through the clevis and tang to connect the fixed element and the pivot element.

4. The system of claim 2 wherein the substrate portion of the fixed element abuts the substrate.

5. The system of claim 4 wherein the first threaded end has a first thread pitch and the second threaded end has a second thread pitch that differs from the first thread pitch.

6. The system of claim 5 wherein the open end of the tubular portion has a cross sectional shape that matches the cross sectional shape of the baluster end.

7. The system of claim 2 wherein the pin has a first end and a second end opposite the first end, the pin defining a longitudinal length extending through the first and second ends, the longitudinal length defining an axis about which the pivot element is capable of pivoting with respect to the fixed element.

8. A baluster attachment system for attachment to a stairway substrate, comprising: a fixed element having a substrate portion and an attachment portion opposite the substrate portion, the substrate portion affixed to the stairway substrate; a pivot element having a secondary attachment portion at a first end and a baluster mount at a second end opposite the first end, the baluster mount adapted to attach to an end of a baluster; and a pin extending through the attachment portion of the fixed element and the secondary attachment portion of the pivot element to pivotally connect the pivot element to the fixed element whereby the pivot element is capable of pivoting about the pin with respect to the fixed element and the stairway substrate until such time that another portion of the baluster is secured in position.

9. The baluster attachment system of claim 8 wherein the fixed element is attached to the stairway substrate with a fastener having a first threaded end and a second threaded end, the first end threaded into the stairway substrate and the second end threaded into the substrate portion of the fixed element.

10. The baluster attachment system of claim 9 wherein the attachment portion of the fixed element includes one of a clevis and a tang, and wherein the secondary attachment portion of the pivot element includes the other of the clevis and tang, the tang extending into the clevis, and the pin extending through the clevis and the tang to pivotally attach the pivot element to the fixed element.

11. The baluster attachment system of claim 10 wherein the baluster mount includes a tubular open end of the pivot element opposite the secondary attachment portion, the tubular open end capable of receiving and retaining a first end of a stairway baluster.

12. The baluster attachment system of claim 11 wherein the baluster mount defines a set screw opening, and the baluster mount includes a set screw extending into the set screw opening for retaining the first end of the stairway baluster in the baluster mount.

13. The baluster attachment system of claim 12 wherein the tubular open end has a cross sectional shape that matches a cross sectional shape of the first end of the stairway baluster.

14. The baluster attachment system of claim 13 wherein the stairway baluster includes a second end opposite the first end, and including a second one of the baluster attachment systems at the second end of the stairway baluster for attaching the second end of the stairway baluster to a second stairway substrate.

15. The baluster attachment system of claim 14 wherein the pivot element of the baluster attachment system is pivoted to a first angle with respect to the fixed element, and wherein the pivot element of the second baluster attachment system is pivoted to a second angle with respect to the fixed element of the second baluster attachment system, the first angle different from the second angle.

16. The baluster attachment system of claim 15 wherein the pin of the baluster attachment system extends parallel to the pin of the second one of the baluster attachment systems.

17. A method for attaching a baluster to a stairway substrate, the method including the steps of: providing a fixed element having a substrate portion at a first end and an attachment portion at a second end opposite the first end; providing a fastener having a first threaded end; securing the fixed element to the stairway substrate by the first threaded end of the fastener; providing a pivot element having a secondary attachment portion and a baluster mount; attaching a first end of a stairway baluster to the baluster mount to secure the stairway baluster to the pivot element; positioning the secondary attachment portion of the pivot element adjacent to the attachment portion of the fixed element with the pivot element extending at a desired angle with respect to the fixed element; and inserting a pin through the attachment portion of the fixed element and the secondary attachment portion of the pivot element to connect the pivot element to the fixed element at the desired angle.

18. The method of claim 17 wherein the baluster mount of the pivot element is a tubular section with an open end, and the step of attaching the first end of the stairway baluster method includes inserting the first end of the stairway baluster into the open end.

19. The method of claim 18 including providing a set screw opening in the baluster mount, and inserting a set screw into the set screw opening to engage the first end of the baluster and retain the baluster in the baluster mount.

20. The method of claim 19 including securing the second end of the baluster to a second stairway substrate using a second fastener, fixed element, pivot element and pin.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is an exploded view of a baluster mounting system according to one embodiment of the present invention.

[0009] FIG. 2 is a perspective view of the baluster mounting system affixed to a stairway substrate.

[0010] FIG. 3 is a side view of the baluster mounting system in use with multiple balusters in a vertical orientation.

[0011] FIG. 4 is a cross sectional exploded view of the baluster mounting system.

[0012] FIG. 5 is a cross sectional view of the baluster mounting system affixed to a stairway substrate.

[0013] FIG. 6 is a side view of a baluster mounting system in an installed configuration.

[0014] FIG. 7 is a side view of the baluster mounting system in use with multiple balusters in an alternative vertical orientation.

[0015] FIG. 8 is a side view of a baluster mounting system in an alternative installed configuration.

[0016] FIG. 9 is a side view of the baluster mounting system in use with multiple balusters in a horizontal configuration.

[0017] FIG. 10 is a side view of a baluster mounting system in a horizontal installed configuration.

[0018] FIG. 11 is a side view of a baluster mounting system in an alternative horizontal installed configuration.

[0019] FIG. 12 is an exploded view of a baluster mounting system according to an alternative embodiment.

[0020] FIG. 13 is a cross sectional exploded view thereof.

[0021] FIG. 14 is a cross sectional view thereof.

DESCRIPTION OF THE CURRENT EMBODIMENTS

[0022] A system 10 for attaching a baluster 12 to a stairway substrate 14 is shown in the Figs. The system 10 generally includes a fastener 16, a fixed element 18 and a pivot element 20. The pivot element 20 is connected to the fixed element 18 with a pin 22 that enables attachment of the pivot element 20 to the fixed element 18 at a desired angular orientation about an axis 23 between the fixed element 18 and the pivot element 20, depending on the particular style of stairway.

[0023] The fastener 16 may be one of a variety of fasteners, and in the illustrated embodiment, is in the form of a fastener commonly referred to as a hanger bolt, or in some cases referred to as a lag bolt or screw, having threaded areas at both ends. As shown, the fastener 16 includes a first end 30 and a second end 32 opposite the first end 30. The first end 30 is included in a first threaded section 34 extending from the first end 30, the first end 30 forms a point 36 in the manner of a lag screw and the first threaded section 34 includes threads 38 having a first predetermined thread pitch. The second end 32 is generally flat, in the manner of a bolt, and is included in a second threaded section 40 extending from the second end 32. The second threaded section 40 includes threads 42 having a second predetermined thread pitch, which may be different from the first thread pitch.

[0024] The fixed element 18 attaches adjacent to the substrate 14 and provides a fixed base for attachment of the pivot element 20. In one embodiment, the fixed element 18 includes a first end 44 and a second end 46. As illustrated, the first end 44 faces the substrate 14 and forms a substrate portion 48. The second end 46 is opposite the first end 44 and forms an attachment portion 50. In one embodiment, the substrate portion 48 is generally cylindrical, and includes a threaded opening 52 extending into the first end 44 for threading onto the second threaded section 40 of the fastener 16. With reference to FIG. 2, the depth of the threaded opening 52 may be such that the substrate portion 48 is capable of threading onto the fastener 16 until the first end 44 abuts with and is flush against the substrate 14. The internal threads of the threaded opening 52 may have a thread pitch that is predetermined to match that of the second threaded section 40 of the fastener 16. The attachment portion 50 may have various configurations for attaching to the pivot element 20, and in the illustrated embodiment, the attachment portion 50 includes a clevis 60 having a pair of spaced apart flanges 62 defining a clevis opening 64 between them. Each flange 62 defines a pin hole 66 for receiving the pin 22. In an alternative embodiment, the fixed element 18 may have a cross sectional shape other than the circular cross sectional shape shown in the Figs. to enable the cross sectional shape of the fixed element 18 to match the shape of the baluster 12 or otherwise provide a desired aesthetic appearance.

[0025] The pivot element 20 pivotally connects to the fixed element 18 and provides an attachment point for the baluster 12. In one embodiment, the pivot element 20 includes a first end 70 and a second end 72 opposite the first end 70. The first end 70 forms a secondary attachment portion 74 for connecting to the fixed element 18. In one embodiment, the secondary attachment portion is a tang 76 that is sized and shaped to interfit into the clevis opening 64 between the flanges 62 of the clevis 60 of the fixed element 18, and the tang 76 defines a pin hole 78 that aligns with the pin holes 66 on the flanges 62 of the clevis 60 when the tang 76 is inserted into the clevis 60. Of course, in an alternative embodiment, the clevis 60 and tang 76 could be swapped, such that the clevis 60 was positioned on the pivot element 20 and the tang 76 positioned on the fixed element 18.

[0026] The second end 72 of the pivot element 20 forms a baluster mount 80 for attaching to a baluster 12. With reference to FIGS. 1 and 2, for example, the baluster 12 may include a first end 90, and the baluster mount 80 is formed as a tubular section of the pivot element 20 including an opening 92 at the second end 72 for receiving the first end 90 of the baluster 12. In one embodiment, the tubular section includes a sidewall 94 that defines a set screw opening 96 for receiving a set screw 98. With the first end 90 of the baluster 12 inserted into the baluster mount 80 through the opening 92, the set screw 98 may be inserted into the set screw opening 96 and tightened to engage the baluster 12 and retain the baluster 12 within the baluster mount 80. In the illustrated embodiment, the baluster 12 has a generally circular cross section and the tubular section of the baluster mount 80 is provided with a circular cross section to match the shape of the baluster 12 and provide a tight fit for the baluster 12. Other shapes of the tubular section and the baluster 12 may be used, depending on the desired appearance of the baluster 12 and the pivot element 20.

[0027] In the illustrated embodiment, the pin 22 is provided for connecting the pivot element 20 to the fixed element 18 via the pin holes 66 in the clevis 60 and the pin hole 78 in the tang 76. When the tang 76 is inserted into the clevis opening 64, the pin 22 is inserted through the aligned pin holes 66, 78. The pin 22 may have opposing ends 100, and may define a longitudinal length between the opposing ends 100. The longitudinal length of the pin 22 generally forms a pivot axis 23 along which the pin 22 is inserted and about which the pivot element 20 may be pivoted or angled with respect to the fixed element 18. In one embodiment, the fixed element 18 is positioned such that the longitudinal length of the pin 22 is aligned in a desired direction. For example, as shown in FIG. 2, the pin 22 is aligned perpendicular to the stairway substrate 14 to which it is attached.

[0028] Installation of a baluster 12 with the mounting system 10 is generally initiated by selecting a desired attachment location on a stairway substrate 14, and then drilling a hole into the substrate 14 at the desired location and in the desired size for inserting the fastener 16. The first end 30 is then inserted into the hole by threading the first threaded section 38 into the hole until the entirety, or substantially all, of the first threaded section 38 is lodged within the hole. Alternatively, the first end 30 of the fastener 16 could be directly inserted into the substrate without a pre-drilled hole.

[0029] With the first end 30 of the fastener 16 embedded in the substrate 14, and the second end 32 projecting out of the substrate 14, the fixed element 18 is attached to the substrate 14 by threading the fixed element 18 onto the second threaded section 40 of the fastener 16. The fixed element 18 may be threaded onto the fastener 16 until the first end 44 abuts the substrate 14 and is flush with the substrate 14. The fixed element 18 may be adjusted as it is attached in order to orient the attachment portion 50 in a desired direction. For example, in the illustrated embodiment where the attachment portion 50 includes a clevis 60, the clevis 60 may be oriented in a desired direction to align the pin holes 66 such that the pin 22 is inserted in a desired direction to provide pivoting of the pivot element 20 in a desired direction. In one embodiment, the clevis 60 may be positioned such that the pin 22 is inserted perpendicular to the elongated direction of the stairway substrate 14.

[0030] In one embodiment of the invention, the baluster 12 is then connected to the pivot element 20. More specifically, the baluster 12 is connected to the pivot element 20 via the baluster mount 80. In the illustrated embodiment, this is completed by inserting the first end 90 of the baluster 12 into the tubular section of the pivot element 20 through the opening 92 at the second end 72 of the pivot element 20. The first end 90 is inserted beyond the set screw opening 96, and the set screw 98 is inserted into the opening to engage the baluster 12 and retain the pivot element 20 on the baluster 12. In a similar fashion, a second one of the pivot elements 20, of a second one of the baluster mount systems 10, may be connected to the second end 91 of the baluster 12, such that both ends of the baluster 12 are attached to a pivot element 20. The secondary attachment portions 74 of each of these pivot elements 20 may be aligned with each other so that the pin holes 78 of each pivot element 20 are aligned and extend in the same direction.

[0031] Each pivot element 20 is connected with an associated fixed element 18. In one embodiment, this connection is enabled by the insertion of the pin 22. The pivot element 20 is positioned such that the tang 76 is inserted into the clevis opening 64 and the pin hole 78 is aligned between the pin holes 66. The pin 22 is inserted through each of the pin holes 66 in the clevis 60 and the pin hole 78 in the tang 76 to connect the pivot element 20 to the fixed element 20. In one embodiment, a pivot element 20 at the second end 91 of the baluster 12, is similarly attached to an associated fixed element 18 via the insertion of an associated pin 22. Notably, one or more of the pivot elements 20 may be oriented at an angle with respect to the associated fixed element 18 when the pin 22 is inserted to make the connection between the pivot element 20 and the associated fixed element 18. Conveniently, the pin 22 can be inserted to connect the pivot element 20 to the fixed element 18 with the fixed element 18 at one of a variety of orientations with respect to the pivot element 20. For example, in the arrangement of FIG. 6, which is described in more detail below, the baluster mount system 10 at the first end 90 of the baluster 12 is connected with the fixed element 18 in vertical alignment with the pivot element 20, whereas the baluster mount system 10 at the second end 91 of the baluster 12 is connected with the fixed element 18 extending at an angle a with respect to the associated pivot element 20.

[0032] Various embodiments of stairway systems are shown in the Figures to illustrate applications of the baluster attachment system 10. In each arrangement, the system 10 is used to attach a series of balusters 12 to a stairway substrate 14, and the particular style and orientation of the substrate 14 may vary from application to application. For example, FIG. 3 shows a first style of stairway 200 that includes a set of treads 202 and risers 204 supported on a cut stringer 206. In this arrangement, the first end 90 of each of the balusters 12 is attached to one of the treads 202 using a first one of the baluster mount systems 10, and the second end 91 is attached to a handrail 208. In this arrangement, the fastener 16 at the first end 90 is embedded into the tread 202, and the fastener at the second end 91 is embedded into the handrail 208. The pivot element 20 and fixed element 18 at the first end 90 are connected such that they are generally in vertical alignment with each other, while the pivot element 20 and fixed element 18 at the second end 91 are angled at about a 45 degree angle with respect to one another as a result of the angle of the handrail 208 with respect to the vertical balusters 12. FIG. 6 shows a close up view of a single baluster 12 attached to this stairway 200.

[0033] FIG. 7 illustrates a second style of stairway 300 that includes a set of treads 302 and risers positioned behind a closed stringer 304. In this arrangement, the first end 90 of each of the balusters 12 is attached to the closed stringer 304 using a first one of the baluster mount systems 10, and the second end 91 of each of the balusters 91 is attached to the handrail 308. As a result of both the closed stringer 304 and handrail 308 extending at an angle with respect to the vertical balusters 12, the pivot element 20 and fixed element 18 at the first end 90 are angled with respect to one another, and the pivot element 20 and fixed element 18 at the second end 91 are also angled with respect to one another. Yet the baluster mount system 10 makes both connections easy by attaching the pivot elements 20 to both ends 90, 91, and then connecting each to their respective fixed elements 18 with respective pins 22. FIG. 8 shows a close up view of a single baluster 12 attached to this stairway 300.

[0034] FIG. 9 illustrates a third style of stairway 400 that shows the balusters 12 attached between a first newel post 402 and a second newel post 404. In this arrangement, the fixed elements 18 are each mounted in a horizontal orientation to a respective one of the posts 402, 404. The balusters 12 extend at an angle with respect to horizontal, such that each pivot element 20 is angled with respect to its associated fixed element 18. As with all of the illustrated embodiments, the pins 22 of each baluster mount 10 are aligned with the pins 22 of all other baluster mounts 10 such that all pivot elements 20 are capable of pivoting on an angle in the same direction. FIG. 10 shows a close up view of a single baluster 12 attached to this stairway 400. FIG. 11 shows a close up view of a single baluster 12 in an alternative horizontal arrangement, for example where the baluster 12 is mounted between newel posts 502, 504 of a horizontal railing section. In this arrangement, the pivot elements 20 at each end of the baluster 90, 91 are aligned with their associated fixed elements 18. The ability of the pivot elements 20 to be connected to their associated fixed elements 18 at any angle enables the use of this baluster mount system 10 with any of the illustrated embodiments, as well as with a variety of stairway embodiments not specifically illustrated in the present application. As noted above, although the fixed element 18 and pivot element 20 of the baluster mount system 10 are illustrated as being cylindrical, other cross sectional shapes may be used in order to match the shape of the baluster 12, or otherwise provide an ornamental property as desired for the particular application.

[0035] An alternative embodiment of the baluster mount system 10 is shown in FIGS. 12-14. In this embodiment, the fastener 16 is replaced with an alternative fastener 16, which may be a wood screw 16 having a single threaded section 34. As shown, the fastener 16 includes a first end 30 and a second end 32 opposite the first end 30. The first end 30 is included in the threaded section 34 extending from the first end 30, the first end 30 forms a point 36 in the manner of a wood screw and the first threaded section 34 includes threads 38 having a first predetermined thread pitch. The second end 32 is a generally conventional screw head.

[0036] In this alternative embodiment of the baluster mount system 10, the fixed element 18 attaches adjacent to the substrate 14 and, similar to the first embodiment, provides a fixed base for attachment of the pivot element 20. In this embodiment, the fixed element 18 includes a first end 44 and a second end 46. As illustrated, the first end 44 faces the substrate 14 and forms a substrate portion 48. The second end 46 is opposite the first end 44 and forms an attachment portion 50. In this embodiment, the substrate portion 48 is generally cylindrical, and as shipped by the manufacturer, includes a closed first end 44 (i.e., with no threaded opening 52). In this embodiment, a threaded opening 52 is formed into the fixed element 18 by the wood screw 16 by inserting the wood screw 16 through the second end 46 of the fixed element 18 and driving the wood screw 16 through the substrate portion 48 and the first end 44 and into the substrate 14. With reference to FIG. 14, the wood screw 16 is driven through the first end 44 and into the substrate 14 to a depth such that the substrate portion 48 is flush against the substrate 14. The attachment portion 50 of this embodiment may attach to the pivot element 20 in the same manner as described above in connection with the first embodiment.

[0037] Installation of a baluster 12 with the mounting system 10 is generally initiated by selecting a desired attachment location on a stairway substrate 14, positioning a fixed element 18 at the desired location, and then drilling a hole through the substrate portion 48 and through the first end 44 and into the substrate 14 at the desired location until the wood screw 16 is substantially fully inserted and the first end 44 is flush with the substrate 14.

[0038] As in the first embodiment, the fixed element 18 may be adjusted as it is attached in order to orient the attachment portion 50 in a desired direction, and the baluster 12 is then connected to the pivot element 20, and a second one of the pivot elements 20, of a second one of the baluster mount systems 10, is connected to the second end 91 of the baluster 12, such that both ends of the baluster 12 are attached to a pivot element 20, and each pivot element 20 is connected with an associated fixed element 18 by the insertion of the pin 22.

[0039] Directional terms, such as vertical, horizontal, top, bottom, upper, lower, inner, inwardly, outer and outwardly, are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).

[0040] The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles a, an, the or said, is not to be construed as limiting the element to the singular.