US20040025452A1

US20040025452A1 - Baluster retaining member

Info

Publication number: US20040025452A1
Application number: US10/216,649
Authority: US
Inventors: Frederick McLean
Original assignee: Bw Creative Wood Industries Ltd
Current assignee: Bw Creative Wood Industries Ltd
Priority date: 2002-08-12
Filing date: 2002-08-12
Publication date: 2004-02-12
Also published as: CA2436676A1; GB0318884D0; US20040177586A1

Abstract

A baluster retaining member for connecting an end of a baluster to an opening in a rail of a railing system includes a rail section dimensioned to fit within the opening and a baluster section dimensioned to be secured to an end of the baluster. The rail and baluster sections are oriented with respect to one another at a predetermined angle so that when the baluster is connected to the rail by the member and the rail is positioned for use adjacent a stairway at an angle from the horizontal, the baluster is oriented vertically.

Description

BACKGROUND OF THE INVENTION

i) Field of the Invention

This invention relates to a retaining member for connecting balusters to rails of a railing system and more particularly relates to a system which permits vertical orientation of balusters into rails having openings perpendicular to the longitudinal axis of the rails, where the rails are oriented at an angle from the horizontal when adjacent a stairway.

ii) Related Art

Railing systems which are made up of upper and lower rails with balusters interposed between the rails are well known in the art. As well, a railing system in which the balusters are inserted into openings in a surface of each rail are well known. In those systems, the upper and lower rails are rigidly connected to posts on each end with the balusters interposed between the rails fitted within openings in the lower surface of the upper rail and the upper surface of the lower rail to hold the balusters in place. The balusters are manually oriented in a vertical direction, irrespective of the angle at which the rails are oriented. Because rails positioned adjacent a stairway or set of stairs must be angled downwardly at an angle corresponding to the angle of the stairway (that is the angle corresponding to the “run” and “rise” of the stairway), difficulties can arise in providing a method for orienting the balusters vertically when interposed between rails which are angled from the horizontal.

In the past, one method of manufacturing rails for this type of railing system was to orient the openings in each rail into which an end of a baluster is inserted at an angle in relation to the longitudinal axis of the rail sufficient to result in a vertical baluster orientation when the rails are angled in use adjacent a stairway. This has meant that special tooling equipment, or time consuming adjustment of existing equipment had to be undertaken to drill these openings at the appropriate angle. Furthermore, some railing systems are sold, without any pre-drilled openings, to consumers and contractors who install these systems. Consumers or contractors are then required to drill openings of appropriate size and orientation in order to accept the balusters between the rails when the railing system is assembled. It is much easier for those consumers or contractors to drill openings in the rails which are perpendicular to the longitudinal axis of those rails, as compared to attempting to drill a plurality of openings at the same angle, corresponding to the rise angle of the stairway, to provide a consistent vertical orientation of a plurality of balusters between the rails when those rails are positioned adjacent a stairway at an angle from the horizontal. This difficulty is compounded by the need to ensure that openings in the top rail align with openings in the bottom rail. As well, the ability to use rails which have an opening perpendicular to the longitudinal axis of the rail permits consumers and contractors to use the same rails for use in a railing system adjacent a set of stairs as are used in a railing system adjacent a horizontal surface. In addition, the rails may be oriented with a particular end either at the high end of the stairway, or the low end of the stairway, whereas rails having angled openings are required to be oriented in one direction to properly align the openings so that the balusters are oriented vertically.

As a consequence, there is a need for a railing system which permits the use of rails having openings to accept balusters between the rails which are formed into the rails in a direction perpendicular to the longitudinal axis of the rails and which enables vertical orientation of the balusters interposed between the rails when the rails are oriented at an angle from the horizontal such as when the rails are used adjacent a stairway.

SUMMARY OF THE INVENTION

This invention provides a railing system for a stairway which includes a pair of rails, each having a plurality of openings extending laterally into one side of the rails in a direction perpendicular to the longitudinal axis of the rails. A plurality of balusters are provided for extending between the rails and a plurality of retaining members are provided for connecting an end of a baluster to one of the openings. The retaining members include a rail section dimensioned to fit within the opening and a baluster section dimensioned to be secured to an end of the baluster. The rail and baluster sections are oriented with respect to one another at a predetermined angle so that when the balusters are connected to the rails by the members and the rails are positioned for use adjacent a stairway at an angle from the horizontal, the balusters are oriented vertically.

In a further embodiment, the rail section is of an outer diameter and the opening is of a corresponding diameter to provide a friction fit of the rail section within the opening.

In a further embodiment, the baluster includes a baluster opening at one end dimensioned to accept the baluster and of the retaining member into the baluster opening.

In a further embodiment, the baluster section is of an outer diameter and the baluster opening is of a corresponding diameter to provide a friction fit of the baluster section within the opening.

In a further embodiment, the rail section is connected to the opening by a tighter fit resulting in a higher level of friction fit as compared to the baluster section and the baluster opening.

In a further embodiment, the predetermined angle is between 30 degrees and 36 degrees.

In a further embodiment, the predetermined angle is about 32.5 degrees.

In a further embodiment, the baluster section is contoured with a frusto-conical outer periphery with the larger diameter at the end adjacent the rail section.

In a further embodiment, the rail section includes a plurality of ribs defining the outer periphery of the rail section.

In a further embodiment, the baluster section comprises a plurality of ribs defining the outer periphery of the baluster section.

In a further embodiment, the baluster section is of a lesser diameter than the rail section and a lip is formed at the region where the rail and the baluster sections meet.

In a further embodiment, the lip defines a lip plane that is perpendicular with the outer periphery of the rail section.

In a further embodiment, the lip acts as a contact region contacting the end of the baluster when the baluster is attached to the baluster section, the lip preventing further insertion of the baluster section into the baluster.

In a further embodiment, the rail section is dimensioned in length equal to the depth of the opening so that when the rail section is in the opening contacting the end of the opening, the lip plane is coplanar with a plane defined by the side of the rail into which the opening extends so that when the baluster is attached to the baluster section to cover the entire baluster section, the lip acts as a contact region contacting the end of the baluster.

In a further embodiment, the ends of the baluster are parallel with one another and form a plane which is at a baluster-end angle with respect to the longitudinal axis of he baluster.

In a further embodiment, the baluster end angle is the same as the predetermined angle.

DRAWINGS

By way of example, specific embodiments of the invention will now be described, with reference to the accompanying drawings, in which: [0023]
FIG. 1 is a perspective view of a rail system of the present invention, adjacent a stairway; [0024]
FIG. 1A is a close-up view of a section of FIG. 1 showing a retaining member of the present invention connecting a lower end of a baluster to an opening in the lower rail of the railing system; [0025]
FIG. 2 is a perspective view of the railing system of FIG. 1; [0026]
FIG. 2A is a close-up view of a section of FIG. 2 in an exploded view showing a baluster interposed between upper and lower rails with baluster retaining members interposed between each end of the baluster and each rail; [0027]
FIG. 3 is a perspective view of a baluster retaining member of the present invention; [0028]
FIG. 4 is a side view of the baluster retaining member of FIG. 3; [0029]
FIG. 5 is a front view of the baluster retaining member of FIG. 3; and [0030]
FIG. 6 is a rear view of the baluster retaining member of FIG. 3.[0031]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring initially to FIGS. 1 and 1A, [0032] railing system 10 is shown adjacent stairway or set of stairs 12. Railing system 10 includes balusters 14 interposed between upper rail 16 and lower rail 18.
Stairway [0033] 12 includes a pair of parallel-spaced opposed stringers 20 and 22 attached at an upper end to beam 24. Lower ends of stringers 20 and 22 rest on a support surface (not shown). A plurality of tread members 26 are positioned horizontally on corresponding plurality of vertical support sections 27 of stringers 20 and 22.
A [0034] typical stairway 12 has a 7 inch rise 30 and a 11¼ inch run 32 which is equivalent to a rise angle 28 from a horizontal support surface of about 32.5 degrees.
[0035] Railing system 10 includes upper post 34 and lower post 36. Upper post 34 is secured to a top face 38 of beam 24 and lower post 36 is attached to, or rests on, the support surface and is attached to a lower region of stringer 22. Lower post 36 may further be attached to the lowermost tread member 26 at notch 40. Upper and lower rails 16 and 18 are positioned between the posts 34 and 36 and extend downwardly from upper post 34 to lower post 36 at an angle of about 32.5 degrees from the horizontal so as to correspond with rise angle 28 of stairway 12. Upper and lower rails 16 and 18 have parallel ends which are cut at an angle of about 32.5 degrees from that perpendicular to the longitudinal axis of rails 16 and 18 which also corresponds to the rise angle 28. When railing system 10 is assembled adjacent stairway 12, rails 16 and 18 are attached to a side of posts 34 and 36 so that the ends of rails 16 and 18 lie flush with adjacent sides of posts 34 and 36. This ensures that the angle of rails 16 and 18 from the horizontal, that is angles 80 and 82 shown in FIG. 2A, correspond to rise angle 28 ensuring that rails 16 and 18 are positioned generally at an angle from the horizontal corresponding to rise angle 28 of stairway 12.
A plurality of [0036] balusters 14 are interposed between rails 16 and 18 and are rigidly secured between those rails in a vertical orientation, while rails 16 and 18 are oriented at an angle from the horizontal as discussed above. Referring to FIGS. 1A and 2A, in order to provide for a vertical orientation of balusters 14 in conjunction with rails 16 and 18 which are angled from the horizontal by angles 82 and 80, retaining members 42 are employed to attach balusters 14 to rails 16 and 18. Upper face 44 of rail 18 includes a plurality of openings 46 extending laterally into face 44, representing a side of rail 18, in a direction perpendicular to face 44 also perpendicular to the longitudinal axis of rail 18.
Retaining [0037] member 42 fits within opening 46 and includes rail section 64 which is dimensioned in width with respect to the width of opening 46 to provide a friction fit engagement within opening 46. Baluster 14 includes opening 48 in an end of baluster 14 into which baluster section 62 of retaining member 42 may be inserted. Baluster section 62 of retaining member 42 is dimensioned in width with respect to opening 48 to provide a friction fit engagement with opening 48 into which baluster section 62 retaining member 42 is inserted. This is best seen in FIG. 2A.
As best depicted in FIGS. 2 and 2A, [0038] upper rail 16 includes a lower face 50 into which a plurality of openings 52 are formed. Openings 52 extend laterally into face 50 and thereby into one side of rail 16. Openings 52 are of the same diameter and length as openings 46. Openings 52 extend in a direction perpendicular to face 50 and perpendicular to the longitudinal axis of rail 16. Rail section 64 of retaining member 42 and opening 52 are dimensioned to provide a friction fit engagement of rail section 64 within opening 52. Baluster 14 includes an opening (not shown) at its upper end 54, similar to opening 48 in lower end 56 of baluster 14 as described above. Baluster section 62 of retaining member 42 and the opening in end 54 are dimensioned to provide a secure friction fit engagement of baluster section 62 of member 42 within the opening at end 54.
Ends [0039] 54 and 56 are cut at an angle from the longitudinal axis equal to rise angle 28 of about 32.5 degrees and are parallel with one another. This ensures that upper face 58 and lower face 60 are coplanar with faces 50 and 44, respectively. Lower face 60 is shown in its assembled position coplanar with face 44 in FIG. 1A.
Referring to FIGS. 3, 4, [0040] 5, and 6, retaining member 42 is depicted in perspective, side, front and rear views. Retaining member 42 includes baluster section 62 integrally joined to rail section 64. Baluster section 62 includes four ribs 66 oriented at right angles to one another and extending the length of baluster section 62. Ribs 66 are integrally joined with four ribs 68 oriented at right angles with respect to one another of rail section 64. Ribs 68 of rail section 64 are wider than ribs 66 providing a larger diameter 70 as compared to diameter 72 of baluster section 62 (best seen in FIG. 4). While not shown, ribs 66 may be tapered with a larger diameter adjacent ribs 68 to provide a general frusto-conical outer periphery to facilitate insertion of baluster section 62 into baluster 14.
As best seen in FIG. 4, rail section and baluster section are angled with respect to one another at [0041] angle 74 which is equivalent to rise angle 28 of about 32.5 degrees. When rails 16 and 18 are oriented at an angle from the horizontal at angles 82 and 80, respectively, of about 32.5 degrees, rail section 64 may be inserted into opening 46 or opening 52 with baluster section 62 oriented in a vertical direction (see FIG. 1A). As depicted in FIG. 2A, retaining member 42 is inserted into opening 52 so that baluster section 62 faces vertically as is baluster section 62 of retaining member 42 positioned within opening 46 of rail 18. This properly orients baluster 14 in a vertical position as depicted in FIGS. 1 and 2 when attached to both baluster sections 62 of retaining members 42.
[0042] Rail section 64 is dimensioned at diameter 70 which is generally equivalent to diameter of openings 46 and 52 to provide a friction fit of rail section 64 within either one of openings 46 or 52. As well, the length 76 of rail section 64 is equal to the depth of openings 46 and 52. As best seen in FIGS. 3 and 4, because ribs 68 are of larger diameter 70 as compared to diameter 72 of ribs 66, lip 78 is formed at the inner end of ribs 68 where ribs 68 merge with ribs 66. Lips 78 on ribs 68 are in coplanar alignment with each other as ribs 68 are all of equal length 76.
[0043] Length 76 is equal to the depth of openings 46 and 52 and when rail section 64 is positioned within opening 46 or opening 52 with rail section 64 contacting the end of opening 46 or opening 52, lips 78 are in coplanar alignment with the plane of corresponding face 44 or 50. As a consequence, when baluster section 62 is positioned within one of opening 48 or opening in end 54 of baluster 14, lips 48 act as a stop contacting corresponding face 58 or 60 which rests against lip 78, as best depicted in FIG. 1A. This provides additional support to balusters 14 which contacts lips 78, rather than faces 44 or 50 which are generally made of wood or other soft material, softer than material used to construct retaining members 42.
As well, because retaining [0044] members 24 have rail section 64 which is positioned at angle 74 with respect to baluster section 62, equivalent to angles 80 and 82 of rails 18 and 16, balusters 14 are oriented in a vertical position.
The foregoing description of the preferred embodiment has been directed to the most popular rise and run angle of a stairway, namely a 7 inch rise and an 11¼ inch run, resulting in about a 32.5 degree angle from the horizontal. However, other stair angles may also be accommodated and will similarly provide a vertical baluster interposed between rails angled from the horizontal by changing the predetermined angle of the retaining [0045] member 42. For example, other popular stair run/rise ratios are: (i) a rise of 6½ inches and run of 11 inches, resulting in a rise angle of about 30 degrees; (ii) a rise of 7½ inches and run of 10 inches resulting in a rise angle of about 36 degrees; and a rise of 7¼ inches and a run of 10¼ inches resulting in a rise angle of about 35 degrees. By providing a predetermined angle 74 and positioning rails 16 and 18 at angles 82 and 80 equivalent to 30 degrees a rise of 6½ inches and a run of 11 inches can be accommodated. Similarly, a rise of 7½ inches and a run of 10 inches can be accommodated by providing angles 74, 82 and 80 of 36 degrees and a rise of 7¼ and run of 10¼ accommodated by providing angles 74, 82 and 80 of 35 degrees.
Having thus described preferred embodiments of a railing system for a stairway and a baluster retaining member, it will be apparent by those skilled in the art how certain advantages of the present invention have been achieved. It should also be appreciated that various modifications, adaptations, and alternative embodiments thereof may be made within the scope and spirit of the present invention. For example, while specific angles associated with certain run/rise ratios have been described, it should be apparent that the inventive concepts described above would be equally applicable to any number of different rise/run ratios by making appropriate adjustment to [0046] angles 74, 82 and 80, consistent with rise angle 28. Moreover, the words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus, if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself. The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. The described embodiments are to be considered illustrative rather than restrictive. The invention is further defined by the following claims.

Claims

I claim:

1. A railing system for a stair way, comprising:

(a) a pair of rails each having a plurality of openings extending laterally into one side of the rails in a direction perpendicular to the longitudinal axis of the rails;

(b) a plurality of balusters for extending between the rails; and

(c) a plurality of retaining members for connecting an end of a baluster to one of the openings, the retaining members having a rail section dimensioned to fit within the opening and a baluster section dimensioned to be secured to an end of the baluster,

wherein the rail and baluster sections are oriented with respect to one another at a predetermined angle so that when the balusters are connected to the rails by the members and the rails are positioned for use adjacent a stair way at an angle from the horizontal, the balusters are oriented vertically.

2. The railing system of claim 1, wherein the rail section is of an outer diameter and the opening is of a corresponding diameter to provide a friction fit of the rail section within the opening.

3. The railing system of claim 1, wherein the baluster comprises a baluster opening at one end dimensioned to accept the baluster end of the retaining member into the baluster opening.

4. The railing system of claim 3, wherein the baluster section is of an outer diameter and the baluster opening is of a corresponding diameter to provide a friction fit of the baluster section within the opening.

5. The railing system of claim 2, wherein the baluster comprises a baluster opening at one end dimensioned to accept the baluster end of the retaining member into the baluster opening.

6. The railing system of claim 5, wherein the baluster section is of an outer diameter and the baluster opening is of a corresponding diameter to provide a friction fit of the baluster section within the baluster opening.

7. The railing system of claim 6, wherein the rail section is connected to the opening by a tighter fit resulting in a higher level of friction fit as compared to the baluster section in the baluster opening.

8. The railing system of claim 1 wherein the predetermined angle is between 30 degrees and 36 degrees.

9. The railing system of claim 1 wherein the predetermined angle is about 32.5 degrees.

10. The railing system of claim 1, wherein the predetermined angle is about 30 degrees.

11. The railing system of claim 1, wherein the predetermined angle is about 36 degrees.

12. The railing system of claim 1, wherein the predetermined angle is about 35 degrees.

13. The railing system of claim 1 wherein the baluster section is contoured with a frusto-conical outer periphery with the larger diameter at the end adjacent the rail section.

14. The railing system as described in claim 1 wherein the rail section comprises a plurality of ribs defining the outer periphery of the rail section.

15. The railing system as described in claim 1 wherein the baluster section comprises a plurality of ribs defining the outer periphery of the baluster section.

16. The railing system as described in claim 14 wherein the baluster section comprises a plurality of ribs defining the outer periphery of the baluster section.

17. The railing system as described in claim 1 wherein the rail section and baluster section are of unitary construction.

18. The railing system as described in claim 3 wherein the baluster section is of a lesser diameter than the rail section and wherein a lip is formed at the region where the rail and baluster sections meet.

19. The railing system as described in claim 18 wherein the lip defines a lip plane that is perpendicular with the outer periphery of the rail section.

20. The railing system as described in claim 19 wherein the lip acts as a contact region contacting the end of the baluster when the baluster is attached to the baluster section, the lip preventing further insertion of the baluster section into the baluster.

21. The railing system as described in claim 19 wherein the rail section is dimensioned in length equal to the depth of the opening so that when the rail section is in the opening contacting the end of the opening the lip plane is co-planar with a plane defined by the side of the rail into which the opening extends so that when the baluster is attached to the baluster section to cover the entire baluster section the lip acts as a contact region contacting the end of the baluster.

22. The railing system as described in claim 1 wherein the ends of the baluster are parallel with one another and form a plane which is at a baluster end angle with respect to the longitudinal axis of the baluster.

23. The railing system as described in claim 22 wherein the baluster end angle is the same as the predetermined angle.

24. The railing system as described in claim 22 wherein the baluster end angle is between 30 degrees and 36 degrees.

25. The railing system as described in claim 22 wherein the baluster end angle is about 32.5 degrees.

26. The railing system as described in claim 1 further comprising waterproofing material positioned in the opening between the rail section and the opening when the rail section is positioned in the opening.

27. A retaining member for connecting a baluster to a rail of a railing system for use adjacent a set of stairs, the rail having an opening perpendicular to the longitudinal axis of the rail, the retaining member comprising:

(a) a first end dimensioned to be attachable to the baluster;

(b) a second end dimensioned to fit within the opening in the rail; and

(c) the first and second ends attached together at an angle so that the baluster is retained by the opening in the rail in a vertical orientation when the rail is positioned adjacent the set of stairs, the rail angled from the horizontal to correspond to the angle of the set of stairs.