Patent Application
20110253964
The present invention is generally directed to balusters. More particularly, the present invention is directed to a baluster mounting system that facilitates the easy installation, removal and replacement of balusters.
Balusters are any of a number of closely spaced supports for a railing or other structures such as furniture, balconies, decks, fences, staircases, windows and arches. Balusters have typically been a shaft fabricated from stone, metal or wood standing on a unifying footing and supporting a handrail (also known as a banister) of a staircase or railing. Typically a baluster is fashioned with decorative or ornamental features as they are routinely used as artistic pieces rather than just being utilitarian structures. A multitude of balusters are referred to in the trade as a balustrade.
Crafting and assembling a balustrade for a railing or the like is a labor intensive job. A common construction process is to position each baluster along the path of a future railing by securing the baluster at its base. At this time the exact spacing of the baluster is needed and also the balusters themselves must be ready for installation. Typically a newel post or other structural support encompasses the two ends of the balustrade, as the balustrade itself is typically not a structural member fully supporting the railing or overhead support. After each baluster is properly positioned and secured, a railing or upper support is then attached on top of the balusters. A common practice is that each baluster penetrate a certain distance into the railing or upper support. Also, a common practice is to use a female receptacle which captures the top and bottom ends of the balusters between top and bottom support rails. For example, a railing would need to have pre-fabricated receptacles for each corresponding baluster to reside within. There is little room for error during the construction process. One cannot easily change the spacing between balusters as it would require the disassembly of the whole railing and balustrade assembly. Furthermore, one cannot easily change or replace the balusters themselves as they are permanently constructed as part of the railing.
Balusters of the past have typically been heavy and substantial in size. For instance, balusters have been traditionally formed with wood and stone that was shaped on a lathe. Some balusters were made of iron rods bent and formed into decorative shapes. While beautiful and intricate, these fabrication methods of the past were also very labor intensive. Newer technologies involve using molds and castings for balusters made of concrete, plaster, and plastics. Furthermore, new materials can be used to form balusters, such as extruded metallic tubes and molded plastics. While the manufacturing time of a prefabricated baluster has decreased, there is still a desire by the consumer to be able to customize their own balustrade assembly.
In efforts to satisfy the need for individual customization, decorative lighting has been used in connection with balusters. One simple way of lighting balusters has been to illuminate them with a series of external lights or a single spot light. However, a more aesthetically pleasing design includes decorative lighting integrated into the hollow inside of a baluster such that it radiates outwardly at the flip of a switch through transparent or translucent portions of the baluster. For instance, patent publication number 2008/0298049 A1 teaches a Baluster Lighting Assembly And Method, which is incorporated herein by reference. However, properly spacing each baluster still remains a difficult job to get right the first time. There is no current method for installing more or less balusters once the railing is assembled. Furthermore, after some time a different baluster design or internal lighting color may be desired by the consumer.
Accordingly, there is a need for a baluster mounting system that facilitates the easy installation, removal, adjustment and replacement of individual balusters without the need to remove or disassemble the railing or overhead support. Furthermore, there is a need for a baluster mounting system, if desired but not necessary, to allow each baluster and an internal light emitting diode to be electrically connected to a power cable. Whether a light emitting diode is used or not, the balusters can be easily installed, removed, adjusted, or replaced. The present invention fulfills these needs and provides other related advantages.
The baluster mounting system includes removably locking a baluster between oppositely disposed upper and lower surfaces. A first rail connector is fixed relative to either an upper or lower surface. A second rail connector is fixed relative to either the upper or lower surface which is opposite the first rail connector. A baluster is removably locked between the first and second rail connectors. The first rail connector is configured to slidably receive an end of the baluster and the second rail connector is configured to laterally receive an opposite end of the baluster. A locking sleeve is slidable along a portion of the baluster and configured for locking engagement with the second rail connector.
The locking sleeve is rotatable about the second rail connector to prevent axial movement of the locking sleeve relative to the baluster. The second rail connector includes a C-shaped wall having an upper edge defining an upper opening and a lower edge connected to a base of the second rail connector. An aperture is disposed within the base of the second rail connector and a screw is disposed through the aperture for attaching the second rail connecter to its corresponding surface. The base of the second rail connector can be perpendicular to the baluster or angled to match an angled surface such that the baluster remains upright and vertical. More specifically, the locking sleeve may include a protrusion that is rotatably locked into a recess within the base of the second rail connector to prevent axial movement of the locking sleeve relative to the baluster.
The first rail connector includes a top rail connector and a pierce connector. The pierce connector is disposed between and slidably joined to the top rail connector and baluster. The top rail connector includes a threaded portion and a corresponding threaded sleeve is slidable and rotatable about the baluster.
The top rail connector and pierce connector cooperatively form an electrical cord channel. An aperture is disposed within a base of the top rail connector and a screw is disposed through the aperture for attaching the top rail connector to its corresponding surface. The base of the top rail connector can be perpendicular to the baluster or angled to match an angled surface such that the baluster remains upright. An insulative cover can be disposed between the screw and the electrical cord channel, but is not required.
The baluster is at least partially hollow and includes a light emitting diode attached relative to the pierce connector within the baluster. An electrical cord is captured within the electrical cord channel and in electrical communication with the light emitting diode through the pierce connector. The baluster can take a multitude of shapes and designs and can include portions that are either translucent or transparent.
Other features and advantages of the present invention will become apparent from the following more detailed description, when taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
The accompanying drawings illustrate the invention. In such drawings:
a is a sectional view of the structure of
b is another sectional view of the structure of
As shown in the drawings for purposes of illustration, the present invention for a baluster mounting system is referred to generally by the reference number 10.
The top rail connector 14 is also configured to receive an insulative cover 24. The insulative cover 24 functions as an insulator between the screw 22 and the pierce connector 16. Installed in the pierce connector 16 are piercing prongs 26 that are used to pierce into an electrical power supply. The top rail connector 14 and the pierce connector 16 both have corresponding channels 28 that when combined cooperatively form an electrical cord channel 30 for the capture of an electrical cord 32 as shown in
Referring back to
Many of the component parts described above can be manufactured from various materials known and used today. For instance, injection molding of plastic is a common process suitable for manufacturing the first rail connector 12, the pierce connector 16, the insulative cover 24, the threaded sleeve 36, the second rail connector 40, and the locking sleeve 42. This specification is not intended to limit the manufacturing methods to just the precise forms described herein. The insulative cover 24 should be made from a non-conductive material. It is also desirable to manufacture the top rail connector 14 and the pierce connector 16 also from a non-conductive material to limit any chance of inadvertent electrical shock or leakage.
a is a sectional view of the structure of
It is also to be understood by one skilled in the art that the baluster mounting system 10 doesn't need to incorporate any feature directed towards incorporating the light emitting diodes 66. The baluster mounting system 10 can be used to mount and replace a multitude of balusters 52 that are without the pierce connector 16, the piercing prongs 26, the electrical cord channel 30, the insulative cover 24, the electrical cord 32, and the light emitting diodes 66. For instance, the pierce connector 16 can be incorporated with the top rail connector 14 into a single part thereby comprising the first rail connector 12.
Although several embodiments have been described in detail for purposes of illustration, various modifications may be made to each without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.
