RAILING ASSEMBLY HAVING BALUSTERS WITH LOCKING TABS

Abstract

A quick install baluster is provided for efficiently and installing balusters onto a rail. A railing is formed using a baluster having a tab in sidewall of the baluster proximate an end of the baluster. The tab may be flared outwards such that the end of the baluster including the tab may be inserted into an opening of a rail but the tab prevents removal of the tab and baluster through the opening of the rail.

Claims

1. A railing comprising: a baluster including a tab in a sidewall of the baluster, the tab having a first end connected to the sidewall and a second end disconnected from the sidewall, the first end of the tab being closer to an end of the baluster than the second end of the tab; and a rail having a first wall including an opening defined therethrough, the opening having a shape and size approximately corresponding to a cross-section of the baluster; wherein the second end of the tab flares outward relative to the sidewall such that the tab of the baluster may be inserted through the opening of the rail in a first direction and such that the tab prevents the tab and the baluster from passing through the opening of the rail in a second direction opposite the first direction.

2. The railing of claim 1, wherein the baluster is made of a vinyl material.

3. The railing of claim 1, wherein the tab is one of a pair of tabs in opposing sidewalls of the baluster.

4. The railing of claim 3, wherein the second end of each of the pair of tabs flares outward relative to the sidewall such that a first width between the second ends of the pair of tabs is greater than a second width of the opening of the first wall of the rail.

5. The railing of claim 1, wherein the first direction is a direction from the second end of the tab to the first end of the tab.

6. The railing of claim 1, wherein the baluster includes the tab at one end of the baluster and includes a second tab at another end of the baluster.

7. The railing of claim 1, wherein first and second side portions of the tab between the first end and the second end are severed from the sidewall such that the tab is connected to the sidewall only by the first end.

8. The railing of claim 1, wherein the rail includes a second wall opposite the first wall, the second wall spaced from the first wall a first distance, wherein the second end of the tab is spaced a second distance from the end of the baluster, wherein the second distance is less than the first distance.

9. A railing assembly comprising: a post; a bracket mounted on the post; a rail coupled to the bracket to be at least partially supported by the bracket, the rail having a first wall including an opening therethrough; and a baluster including a pair of tabs in opposing sidewalls of the baluster, each of the pair of tabs having a first end connected to the sidewall and a second end that is disconnected from the sidewall, the first end of the tab being closer to a distal end of the baluster than the second end of the tab; wherein the baluster extends through the opening of the first wall of the rail such that the pair of tabs are positioned inside the rail; wherein the second end of each of the pair of tabs flares outward relative to the sidewall such that a first width between the second ends of the pair of tabs is greater than a second width of the opening of the first wall of the rail.

10. The railing assembly of claim 9, wherein the second ends of the pair of tabs abuts the first wall of the rail to prevent removal of the baluster through the opening of the rail.

11. The railing assembly of claim 9 wherein the baluster is made of a vinyl material.

12. The railing assembly of claim 9, wherein the baluster includes the pair of tabs at one end of the baluster and includes a second pair of tabs at another end of the baluster.

13. The railing assembly of claim 9, wherein first and second side portions of each tab between the first end and the second end are severed from the sidewall such that each tab is connected to the sidewall only by the first end.

14. A baluster for a railing assembly, the baluster comprising: a sidewall; and a tab formed in the sidewall proximate an end of the baluster, the tab having a first end connected to the sidewall and a second end disconnected from the sidewall, the first end of the tab being positioned between the end of the baluster and the second end of the tab; wherein the second end of the tab flares outward relative to the sidewall to provide a locking mechanism when the baluster is inserted through an opening in a rail.

15. The baluster of claim 14, wherein the tab is formed by punching out a portion of the sidewall of the baluster such that the second end and first and second side portions of the tab between the first end and the second end are severed from the sidewall.

16. The baluster of claim 14, wherein the baluster includes a second tab formed in the sidewall proximate another end of the baluster.

17. The baluster of claim 14, wherein the tab is one of a pair of tabs in opposing sidewalls of the baluster.

18. The baluster of claim 17, wherein the second end of each of the pair of tabs flares outward relative to its respective sidewall such that a first width between the second ends of the pair of tabs is greater than a second width of the opening in the rail.

19. The baluster of claim 14, wherein the tab is configured to deflect inwardly when forced through the opening and is configured to return to its outwardly flared position once positioned inside the rail.

20. The baluster of claim 14, wherein the sidewall has a first width and the tab has a second width that is approximately 40-75% of the first width.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:

[0009] FIG. 1 is a side elevation view of a railing assembly in accordance with one embodiment of the present invention;

[0010] FIG. 2 is an exploded perspective view of a portion of the rails and baluster of the railing assembly of FIG. 1;

[0011] FIG. 3 is a side view of a portion of the baluster of FIG. 2;

[0012] FIG. 4 is a section view of the portion of the baluster of FIG. 3, viewed along section 4-4;

[0013] FIG. 5 is an upper view of the baluster of FIG. 2;

[0014] FIG. 6 is a side view of the rails and baluster of FIG. 2 shown in an assembled position;

[0015] FIG. 7 is an enlarged view of a portion of the rail and baluster of FIG. 6;

[0016] FIG. 8 is a section view of the rail and baluster of FIG. 7, viewed along section 8-8; and

[0017] FIG. 9 is an enlarged view of a portion of the rail and baluster of FIG. 6 shown with the baluster in a different orientation.

DETAILED DESCRIPTION

[0018] The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures. It will be appreciated that any dimensions included in the drawing figures are simply provided as examples and dimensions other than those provided therein are also within the scope of the invention.

[0019] The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.

[0020] As shown in FIG. 1, a railing assembly 10 may include uprights, pickets, or balusters 12 extending between and coupled to a top rail 14 and a bottom rail 16 to form a section of railing 18. A railing section 18 may be connected to and supported by posts 20 at each end of the railing section 18 by coupling ends of rails 14, 16 to rail mounts or brackets 22 mounted on the posts 20. In some embodiments, the railing section 18 may be supported by other support structures at one or both ends of the railing section 18, such as building walls or the like.

[0021] As shown in FIG. 2, a rail 14, 16 may include a cutout or opening 24 in a baluster receiving wall 26 (i.e., a bottom wall of top rail 14 or a top wall of bottom rail 16). The opening 24 may approximately correspond to a cross-section of a baluster 12 (e.g., having a similar shape and slightly larger size) such that an end of the baluster 12 may be inserted into the opening 24.

[0022] As shown in FIGS. 2-5, a baluster 12 may include on one or more protrusions or tabs 28 proximate a terminal end 30 of the baluster 12. In one embodiment, the tabs 28 may be formed by punching out a portion of the baluster sidewall 32. A first proximal portion or end 34 of the tab 28 proximate the end 30 of the baluster 12 may remain connected to the baluster sidewall 32 while a second distal portion or end 36 of the tab 28 opposite the first end 34 may be severed, separated, or otherwise disconnected such that it projects outwardly relative to the sidewall 32. Similarly, the intermediate portions 38 of the tab 28 between the proximal or first end 34 and distal or second end 36 may optionally be fully or partially severed, separated, or otherwise disconnected from the sidewall 32 such that the tab 28 is only connected to the sidewall 32 by the first end 34. The tab 28 may be angled, bent, or flared outwards from the first end 34 to the second end 36. The die used to punch out the tab 28 may include edges that cut or sever the second end and sides 38 of the tab 28 and may include a blunt central portion that biases the tab 28 to an outward flare.

[0023] The baluster 12, and consequently the tab 28, may be made of a generally rigid or stiff material, such as vinyl. However, it will be appreciated that the baluster 12, including the tab 28, may be made of other suitable materials that are currently known or developed hereafter. As such, the tab 28 may be forced or deflected or bent inwardly to be generally substantially flush with the baluster sidewall 32. The tab 28 may be biased to return to its outwardly flared state or position once the external force is removed.

[0024] As shown in FIGS. 6-8, ends of balusters 12 may be inserted through openings 24 in the rails 14, 16. As the end of a baluster 12 is inserted through an opening 24, the tab 28 will contact the edge of the opening 24 and provide a biasing force against the baluster 12 being inserted further. Because the tab 28 is flared outward in a direction from the end 30 towards a medial portion of the baluster 12, a user may force or push the baluster 12 further into the aperture or opening 24 thereby flexing the tab 28 inwardly. Once the baluster 12 is forced far enough into the opening 24 such that the tab 28 passes fully through the opening 24 and into a central portion of the rail 14, 16, the tab 28 may once again flare outwardly, which can lock the baluster 12 in the rail 14, 16. Once inserted, the outwardly flared distal or second end 36 of the tab 28 may prevent the tab 28 from exiting the opening 24 by contacting or abutting the baluster receiving wall 26 near the edge of the opening 24.

[0025] An installer may assemble a section of railing 18 including multiple balusters 12 by inserting a first end of each baluster 12 into the openings 24 of one of the top rail 14 or bottom rail 16, and forcing the tabs 28 of each baluster 12 into the opening 24 such that the end of the baluster 12 is locked within the rail 14, 16. The installer may then align and partially insert the opposite or second ends of each baluster 12 into the openings 24 of the other of the top rail 14 and bottom rail 16. Once all the balusters 12 are aligned with the corresponding openings 24, the installer can force the tabs 28 of the balusters 12 into the openings 24 to lock the second end of the balusters 12 within the other rail 14, 16. This section of railing 18 may then be moved by an installer as an entire unit and without the balusters 12 falling out of rails 14, 16. For example, the section of railing 18 may be assembled in a separate area from the final installation area or may be installed while the final installation area is otherwise being prepared (e.g., while other workers install posts or complete other work).

[0026] As shown in the illustrated embodiments, the balusters 12 may include two tabs 28 at each end of the baluster 12. The tabs 28 may be positioned on opposite baluster sidewalls 32. In other embodiments, the baluster 12 may include more or fewer tabs 28 (e.g., one tab, three tabs, four tabs). As shown in FIGS. 6-8, the baluster 12 may be inserted into a rail 14, 16 such that the baluster sidewalls 32 that include the tabs 28 may be oriented perpendicular to rail sidewalls 40, which may extend generally perpendicular from the baluster receiving wall 26. As shown in FIG. 9, the baluster 12 may be inserted into a rail 14, 16 such that the baluster sidewalls 32 that include the tabs 28 may be oriented parallel to rail sidewalls 40. In this orientation, the tabs 28 may frictionally engage the interior of the rail sidewalls 40, which can inhibit movement between the rails 14, 16 and baluster 12.

[0027] As shown in FIG. 4, the proximal or first end 34 of the tab 28 may be a distance D1 from the terminal end 30 of the baluster 12, and the distal or second end 36 may be a distance D2 from the end 30. As shown in FIG. 8, the rail 14, 16 may have a height D3 (i.e., distance between baluster receiving wall 26 and opposing wall 42). A terminal end 30 of the baluster 12 may optionally be configured to abut the opposing wall 42 and stop the baluster 12 from being inserted any further through the opening 24. Similarly, the second end 36 of the tab 28 may abut the baluster receiving wall 26 and prevent the baluster 12 from being pulled any further outward through the opening 24. Thus, the amount of vertical play for a baluster 12 within a rail 14, 16 may be determined by the distance D3 minus the distance D2. The amount of vertical play may be optimized to allow an installer some maneuverability of the balusters 12 and rails 14, 16 while maintaining the balusters 12 and rails 14, 16 in an assembled railing section 18 that can be easily moved by an installer. For example, in one embodiment, distance D1 may be approximately 0.875 inches, distance D2 may be approximately 0.375 inches (resulting in an approximately 0.5-inch-tall tab 28), and distance D3 may be approximately 2 inches (resulting in approximately 1.125 inches of vertical play for a baluster 12 with a rail 14, 16).

[0028] As shown in FIG. 5, a baluster sidewall 32 may have a width W1 and a tab 28 may have a width W2. For example, in one embodiment, width W1 may be approximately 1.375 inches and width W2 may be approximately 0.75 inches. In some embodiments, width W2 may be approximately 40-75% of width W2. As shown in FIG. 2, the opening 24 may have a width W3 that is approximately equal to or slightly smaller than the width W1 of the baluster sidewall 32. As shown in FIG. 4, second ends 36 of opposing tabs 28 may be flared outwards such that the second ends 36 are a width W3 apart, which may be greater than the width W3 of the opening 24.

[0029] Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the invention. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations, locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the invention.

[0030] Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any of the individual embodiments described above. The embodiments described herein are not meant to be an exhaustive presentation of how the various features of the subject matter herein may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

[0031] The numerical ranges in this disclosure are approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the lower and the upper values, in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated, are to be considered to be expressly stated in this disclosure.

[0032] As used herein, a, an, or the can mean one or more than one. For example, an image can mean a single image or a plurality of images.

[0033] The term and/or as used in a phrase such as A and/or B herein can include both A and B; A or B; A (alone); and B (alone). Likewise, the term and/or as used in a phrase such as A, B, and/or C can include at least the following embodiments: A, B, and C; A, B, or C; A or C; A or B; B or C; A and C; A and B; B and C; A (alone); B (alone); and C (alone).

[0034] As used herein, the term about when referring to a measurable value such as an amount, a temporal duration, and the like, can include variations of +/20%, more preferably +/10%, even more preferably +/5% from the specified value, as such variations are appropriate to reproduce the disclosed methods and systems.

[0035] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are inherent to the structure and method. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

[0036] The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms having and including and similar terms as used in the foregoing specification are used in the sense of optional or may include and not as required. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.