Patent Application
20090184303
This invention relates to balustrading, in particular although not exclusively to balustrading for outdoor use.
It is known to provide a balustrade around a deck or other area in an outdoor location. Typically these balustrades are formed, at least in part from wood and may comprise wooden newel posts, rails and balusters. In order to erect such a balustrade it is necessary to have a degree of carpentry and/or building skill. The posts must be installed correctly, the components must be cut accurately and joined together securely to provide a balustrade which is both fit for purpose and has aesthetic qualities e.g. the rails are horizontal, the posts are vertical and so on).
Therefore, there is a need to provide a balustrade system which is easy to install and which, even when installed by the relatively unskilled D-I-Y enthusiast, has the necessary structural and aesthetic qualities.
Accordingly, a first aspect of the invention provides a kit of parts for a balustrade assembly, the kit comprising a length of rail and one or more baluster brackets, the or each baluster bracket comprising an elongate first portion, the elongate first portion and a portion of the rail being complimentarily shaped thereby to engage and retain the elongate first portion along its length to ensure correct orientation, such as a predetermined orientation, of the bracket relative to the rail for subsequently securing a baluster to the bracket, the or each bracket having a second extension portion to which a baluster or panel is securable.
The rail portion and first portion of the bracket are preferably shaped to prevent relative pivoting movement therebetween when engaged.
The rail may comprise a rebate, which rebate may extend along the entire length of the rail. Alternatively a plurality of rebates may be provided therein, each extending partway along the rail.
The first portion of the bracket may comprise one or more securing means, for example, expansion fittings arranged to be expandable and/or contractable.
A second aspect of the invention provides a kit of parts for a balustrade assembly, the kit comprising a length of rail and one or more baluster brackets, the rail having a portion shaped to engage a first portion of the or each baluster bracket to ensure correct orientation of the bracket in use, the first portion comprising securing means including an expansion fitting arranged to be expandable and/or contractable, the or each bracket having a second extension portion to which a baluster or panel is securable
Preferably, the bracket is securable to the rail with said securing means, e.g the expansion fitting, in one of a relatively expanded or relatively contracted condition.
In an embodiment where the rail comprises a rebate, the bracket may be securable to the rail with the expansion fitting located in the rebate and by urging the fitting to a relatively expanded condition. In which case the bracket or rail, or both may comprise an abutment to reduce, and preferably prevent, relative pivotal motion between the rail and the bracket inserted therein. The first portion may comprise a male part, for example having a substantially cylindrical periphery. Optionally, the first portion may comprise a periphery which is substantially cylindrical or of some other shape, which may be formed by interconnected discs, core portions and/or reinforcing ribs.
Preferably, the securing means is provided by two or more segments of the first portion which are separatable, thereby to provide the expansion fitting. More preferably, the segments are formed by a split end of the first portion, thereby providing two facing parts. The facing parts may include opposed rebates, for example arcuate rebates forming part of a circle, arranged to receive an expansion member, for example a screw. The rebates may be tapered to provide a means for controlling the quantum of separation and/or expansion of the expansion member.
The expansion member may comprise a member which frictionally engages the facing parts and/or a member which is secured in place by alternative means such as a bayonet or other suitable securing means.
Alternatively, the bracket may engage an outer surface or extension of the rail and may be secured thereto by securing means, e.g. an expansion fitting in a relatively contracted condition. For example, the fitting may comprise clamping means. The clamping means may comprise opposed concave surfaces whose separation is adjustable, for example c-shaped members secured together by a threaded members, whereby the threaded members allow for adjustment of the clamping means. In such an arrangement one edge of each member may be pivotably secured together, the threaded member adjustably connecting the other edges together.
The securing means may be operable to prevent or restrict relative movement of the bracket in a direction along the rail.
A third aspect of the invention provides a kit of parts for a balustrade assembly, the kit comprising a newel post and a post-to-rail connector, the post having a portion which is complimentarily shaped with a first portion of the connector thereby to engage the post and the connector whereby, in use, horizontal relative motion is restricted but pivotal motion is permitted, the connector having a second portion for connection to a rail.
The post portion and connector first portion are preferably shaped to permit relative pivotal motion therebetween. Preferably one or both of the post and connector comprise an abutment arranged to limit the amount of relative pivotal motion. The degree of relative pivotal motion is preferably limited to describe an angle of less than 90°, preferably from to 80°, more preferably 10 to 70° and most preferably 40 to 60°, say 52°.
In one embodiment the post comprises a rebate and the first portion of the connector comprises a complimentary shaped extension. In one embodiment the rebate describes a major segment of a circle in cross section.
The post may comprise a plurality of shaped portions, for example two, three or four. Preferably the shaped portions are equidistantly spaced around the perimeter of the post.
In a preferred embodiment the post is substantially circular in cross-section and has four shaped portions, for example rebates, which are distributed at 90° angles around the circumference of the post.
The shaped position may be a protrusion to engage the connector.
The connector may comprise securing means, for example an expansion fitting arranged to be expandable and contractable. Preferably the connector is securable to the post with the expansion fitting in one of a relatively expanded or contracted condition.
Where the shaped portion of the post is a rebate the first portion of the connector may be a male part, for example having a periphery which is substantially cylindrical or some other elongate form. At least part of the male part may comprise an expansion fitting to secure, upon expansion, the connector to the post.
Preferably, the securing means is provided by two or more segments of the male part which are separatable, thereby to provide the expansion fitting. More preferably, the segments are formed by a split end of the male part, thereby providing two facing parts. The facing parts may include opposed rebates, for example arcuate rebates forming part of a circle, arranged to receive an expansion member, for example a screw. The rebates may be tapered to provide a means for controlling the quantum of separation and/or expansion of the expansion member.
The expansion member may comprise a member which frictionally engages the facing parts and/or a member which is secured in place by alternative means such as a bayonet or other suitable securing means.
Alternatively, the connector may engage an outer surface or extension of the post and may be secured thereto by securing means, e.g. an expansion fitting in a relatively contracted condition. For example, the fitting may comprise clamping means. The clamping means may comprise opposed concave surfaces whose separation is adjustable, for example c-shaped members secured together by a threaded members, whereby the threaded members allow for adjustment of the clamping means. In such an arrangement one edge of each member may be pivotably secured together, the threaded member adjustably connecting the other edges together.
The extension portion of the connector may comprise a male or female part to engage an end of a rail. Preferably the extension portion is shaped so as to prevent relative rotation of a rail when engaged therewith.
A fourth aspect of the invention provides a kit of parts for a balustrade assembly, the kit comprising a first rail, a second rail and a rail-to-rail connector for connecting the first and second rails in a substantially parallel and spaced apart relationship, the rail-to-rail connector having a first portion shaped to engage one rail and a second portion shaped to engage the second rail, wherein one or both of the first and second portions of the connector are shaped to prevent relative rotation or pivotal motion between the connector and the rail.
Preferably the first and/or second portion of the connector comprises male part for engagement in a rebate located in one or both rails. More preferably, the male part is complimentarily shaped with the rebate.
The cross-section of the first and/or second portion may substantially match the cross-sectional shape of a rail to be inserted therein or thereon. For example, the first and/or second portion may be substantially in the form of at least part of a circle. The first portion may comprise a hollow, substantially cylindrical member and/or the second part may comprise a portion of a hollow, substantially cylindrical member.
The male part may include a projection on an internal surface of the first and/or second portion. The male part may comprise an arcuate cross-section, for example having a crescent shape to provide two arms.
A further aspect of the invention provides a newel post for a balustrade, the post comprising an elongate section having one or more elongate shaped portions extending along at least a part of the length thereof for engagement with a connector.
Preferably the or each shaped portion is a rebate. The rebate may comprise a cross-section substantially in the shape of the major segment of a circle. Alternatively, the rebate may be of any suitable shape, for example elliptical, diamond shaped and so on.
Additionally or alternatively, the rebate may provide a pair of opposed lips, for example to engage a portion of a connector.
The post may comprise a plurality of rebates, preferably equidistantly spaced. The post may be formed as an extruded length, for example of plastics, such as a thermoset resin, or of metal, for example aluminium or a metal alloy.
A further aspect of the invention provides a connector to interconnect an upright post to a horizontal rail, the connector comprising a first portion engageable with a correspondingly shaped portion of a post and a second portion engageable with a correspondingly shaped portion of a rail, wherein the second portion is shaped to prevent or at least restrict relative pivotal motion between the second portion and the rail.
The first portion may comprise an expansion fitting operable to expand and/or contract whereby the first portion may be secured releasably or permanently to a post.
The connector may comprise an abutment to limit or restrict pivotal motion of the connector when engaged with the post.
The second portion may comprise a male or female part for engaging an end of a rail.
A further aspect of the invention provides a rail for a balustrade, the rail comprising an elongate section having one or more elongate rebated portions extending along at least part of the length thereof, for engagement with a connector, wherein the or each rebated portion is arcuate in shape, for example describing a major segment of a circle.
A yet further aspect of the invention provides a hollow rail for a balustrade, the rail comprising an elongate section having one or more elongate rebated portions extending along at least part of the length thereof, for engagement with and retention of a connector, wherein the or each rebated portion is formed by a depression in the wall of the rail.
Preferably the rail is an extruded or pultruded length of plastics, e.g. thermoset resin, or an extruded length of metal, e.g. aluminium.
The rail preferably has the cross-sectioned shape of a crescent. Preferably the distance across the opening of the or each rebated portion is less than the maximum transverse dimension of the rebated portion.
There is further provided, in a further aspect of the invention, a baluster bracket for a balustrade, the bracket comprising a first portion for engagement with a rail and a second portion for engagement with a baluster, the first portion comprising an elongate male part for engagement with a corresponding rebate in a rail.
Preferably the first portion comprises an expansion fitting operable to expand or contract to secure the bracket to a rail.
A further aspect of the invention provides a baluster bracket for a balustrade, the bracket comprising a first portion for engagement with a rail and a second portion for engagement with a baluster, the first portion comprising a male part for engagement with a corresponding rebate in a rail, the male part comprising one or more expansion fittings arranged to be expandable and/or contractable for securing the bracket to the rail.
The bracket may further comprise an abutment to prevent or restrict relative pivotal motion between a rail and the bracket engaged, in use, therewith.
The bracket may be substantially symmetrical.
Preferably, the bracket comprises a marking to indicate a direction of filling.
The bracket may be a moulded plastics one piece member.
A yet further aspect of the invention provides a rail to rail connector for connecting two rails of a balustrade in a substantially parallel and spaced apart relationship, the connector comprising a first portion for shaped for engaging a first rail and a second portion shaped for engaging a second rail, wherein one or both of the first and second parts are shaped to prevent relative rotational or pivotal motion between the connector and a rail, in use, engaged therewith.
Preferably the first part comprises a protrusion shaped for engagement with a corresponding shaped rebate of a rail.
Preferably the protrusion extends into a curved part shaped to at least partially surround at least part of a rail. Preferably the curved part defines a circular aperture.
The connector may be cast or formed from an extruded or pultruded material, for example thermoset resin or aluminium or a metal alloy.
The two parts of the connector may be found by an intervening part, the intervening part preferably being shaped such that, in use, the principal axis of the two rails connected to the connector, are laterally and/or vertically displaced.
Further aspects of the invention relates to kits of parts comprising two or more of the above-identified components.
The or each kit may comprise one or more balusters or panels.
Further aspects of the invention relate to methods of fabrication of a balustrade and to balustrades made from one or more of the above-identified components.
In order that the invention may be more fully understood, it will now be described by way of example only and with reference to the accompanying drawings, in which:
Turning to
The rails 3 are connected to the posts 2 by connectors 5 and the balusters 4 are connected to the rails 3 by baluster brackets 6. A handrail 7 is connected to the upper rail 3A in a substantially parallel and spaced apart relationship by three rail to rail connectors 8 equally spaced along the upper rail 3A.
The individual components of the balustrade 1 will now be described.
Referring to
Turning to
The first part 51 has a circular barrel 511 which at a first end 512 is sub divided into two halves 513, 514, the inner surface of each half 513, 514 carrying threads thereonsuch that a grub screw or other fitting (not shown) may be retained, thereby to provide an expandable fitting.
Screwing the grub screw or other fitting into the barrel 511 causes the two halves 513, 514 to separate from one another. If the halves 513, 514 are not threaded a fitting may be otherwise forced therein to cause expansion of the halves 513, 514.
The second end 515 of the barrel 511 has an arcuate wall 516 upstanding therefrom, the wall 516 having an aperture 517 formed therein.
A bridging wall 53 projects radially from the circumferential surface of the barrel 511 and extends substantially along its length. The bridging wall 53 is connected to a circular plate 54, the wall 53 extending diametrically across the plate 54. The plate 54 has, on its opposite side, a peripheral lip 55 defining a rebated portion 56 from which the second part 52 extends.
The second part 52 is a hollow member having a substantially crescent shaped cross-section to define a longitudinal rebate 521 and a wall 522. Three longitudinal apertures 523 extend approximately half of the length of the second part 52 from the free end thereof towards the plate 54.
The first part 61 is elongate and has a substantially cylindrical periphery which is interrupted and includes reinforcement ribs. Each end of the first part 61 is split into first 611 and second 612 facing parts, each facing part 611, 612 having a substantially semi-cylindrical periphery which is interrupted with reinforcement ribs. Each of the facing parts 611, 612 terminates in a wall 613A, 613B which defines part of a segment of a circle, the two walls 613A, 613B defining a major part of a segment of a circle in concert. In the region of the walls 613A, 613B the facing parts 611, 612 have opposing arcuate rebates 614A, 614B which together provide part of a circular aperture in which a grub screw (not shown) may be retained, thereby to provide an expandable fitting.
Screwing the grub screw into the hole formed by the rebates 614A, 614B causes the facing parts 611, 612 to separate from one another.
A bridging wall 615 projects from the first part 61 and extends along a portion of its length. A pair of outwardly directed wings 63 extend from either side of the bridging wall 615, which wings 63 have a transverse dimension substantially the same as the diameter of the first portion 61. The underside of each of the wings 63 curves to a point of joining to the second part 62.
The second part 62 includes an elongate tab 622 in the form of a substantially flat plate with a rounded end. The tab 622 includes, at its lower end, an elliptical aperture 623 through its thickness.
The lowermost part 81 is in the form of a circular wall into which a radial projection 812 extends. The projection 812 describes a major segment of a circle in cross-section to form a pair of curved arms 813. A through hole 814 extends through the circular wall 811 for receiving fastening means, for example screws (not shown), for securing the bracket 8 to a rail. The lowermost part 81 is integrally formed with the central section 82, which extends upwardly therefrom.
The central section 82 includes a pair of curved facing walls 821, 822, which join the lowermost part 81 to the uppermost part 83, and a pair of strut members 823 extending between the facing walls 821, 822 at an angle. The curved facing walls 821, 822 converge slightly from the lowermost 81 to uppermost parts 82.
The upper part 83 is integrally formed with the curved facing walls 821, 822 of the central section 82. The upper part 83 has a curved wall 831 with a pair of apertures 832 formed through its thickness and marginally spaced from its free edge. The curved wall 831 extends from the outermost facing wall 822 and across the upper edge of the innermost facing wall 821 so as to provide a support surface which is horizontally and vertically displaced with respect to the lower part 81.
In order to install the balustrade 1 of the current invention the following procedure is one example of how this may be carried out.
Generally, if the balustrade 1 is to be used with a deck as a substrate S, the deck foundation (not shown) is first installed.
Typically, the position of the newel posts 2 will be established before fixing deckboards (not shown). In one embodiment of the invention, the maximum achievable span between centres of newel posts 2 is 1904 mm or, if using a single panel arrangement (e.g. 4B of
For every newel post 2 position, a joist (not shown) is usually located on the edge (not shown) and fixed to the joists of the deck (not shown).
Using a template (not shown), the positions of the posts 2 are preferably marked and the centres are drilled to the top of the deckboards.
Pilot holes (not shown) are then drilled through the deckboards (not shown) and to the edge-on joist (not shown) beneath. A base 24 is installed on the deck S using screws (not shown), for example coach screws, to extend through the holes 28 in the lugs 27 and a post 2 is inserted therein such that the projections 26 extend into the rebates 21. The engagement of the projections 26 with the rebates 21 ensures that the post 2 is not able to rotate relative to the fixed base 24.
The newel post base covers 203 are inserted over the posts 2 so that they are flush with the top of the deck S. The cover 203 is fixed to the newel posts by drilling pilot holes (not shown) through the aperture 209 of the cover 203 and into the post 2 and using self tapping screws (not shown). It will be appreciated that radial projections 207B each extend into one of the rebates 21 of the post 2 such that the two opposing upstanding walls 208 lie adjacent the wall of the rebate 21 of the post 2. The engagement of the radial projections 207B with the rebates 21 ensures that the cover 203 is located accurately over the base 24.
The upper rails 3A and lower rails 3B are then cut to length.
A bead of silicone sealant is then applied to the rebated portion 56 of each of a plurality of connectors 5, the second part 52 of which is then inserted into one end of each lower rail 3B by aligning the rebate 521 of the second part 52 with the rebate 31 of the lower rail 3B. Each connector 5 is then screwed to its respective lower rail 3B using self tapping screws (not shown). The end of the lower rail 3B engages or abuts the rebated portion 56 such that the lip 55 overlies the end of the lower rail 3B while the silicone sealant ensures a sealed connection. The engagement of the rail rebate 31 with the connector rebate 521 ensures accurate and pre-determined registration of the components.
After the number of baluster brackets 6 required has been calculated, the requisite number can be inserted on to each of the aforementioned lower rails 3B.
The first part 61 of each baluster bracket 6 is slid into the lower rail 3B making sure that a notch mark (not shown) on the brackets 6 all face in the same direction.
A bead of silicone sealant is applied to the rebated portion 56 of a further plurality of connectors 5, which are then fitted into the other end of each of the aforementioned lower rails 3B in a similar manner to that described above.
Using timber or other packers (not shown) to define the desired height above the deck and with the notches (not shown) of the brackets 6 all facing outwards away from the deck, each assembly 3B, 5, 6 is slid between the posts 2 such that the first part 51 of each connector 5 is located within a rebate 21 of the post 2 until it rests on the timber packers (not shown).
A grub screw is then inserted in the barrel 511 to force the halves 513, 514 apart to secure the barrel 511 within the rebate 21. A hole can be drilled through the aperture 517 and into the post 2 if required using a self tapping screw in order to further secure the two components together.
The same operation is carried out at the other end of the lower rails 3B.
As will be appreciated the same operation is carried out for the top rail 3A except that, in addition, the rail-to-rail connectors 8 are also located over the upper rail 3A. After the space between each baluster 4 and the space between each rail-to-rail connector 8 is established, the order in which the components 4, 8 must be inserted may then be determined.
In the embodiment shown in
The rail-to-rail connector 8 is located over the upper rail 3A such that the circular wall 811 encompasses the rail 3A and the projection 812 is retained within the rebate 31. The engagement of the projection 812 with the rebate 31 prevents relative rotation between the two components 3A, 8 and ensures accurate and pre-determined registration thereof.
As described above in relation to the lower rails 3B, the top rail 3A is then located in place using timber battens (not shown) and secured to the posts 2 using grub screws (not shown) and self-tapping screws (not shown) extending through apertures 517.
The baluster brackets 6 are placed at appropriate points, for example using a spacer or template, along the top 3A and bottom 3B rails 3 and secured thereto by screwing the grub screws (not shown) into the circular apertures formed by the rebates 614A, 614B in the facing parts 611, 612. As previously mentioned, screwing the grub screws (not shown) causes the two walls 613A, B to be forced apart from one another thereby to engage the walls of the rebate 31.
The wings 63 abut and overlie the lips 33 of the rebate 31 of the rail 3 to prevent relative rotational movement between the bracket 6 and the rail 3. This ensures that the brackets 6 are accurately registered and that they always depend, or extend, perpendicularly from the principal axis of the rail 3, as the case may be.
Balusters 4 are then connected to the baluster brackets 6 using appropriate fixing means, for example screws (not shown), fastened to the balusters 4 through the holes 623 of the baluster brackets 6.
A cap 200 is then preferably inserted into the free upper end of each of the newel posts 2 such that each of the legs 201 are located within one of the rebates 21. Screws (not shown) are then fastened to the newel posts 2 through the holes 202 in the legs 201.
The distance between the lips 33 of the rail 3 and between the lips 23 of the post 2 are substantially the same in the embodiment described herein. Lengths of silicone strip 9 are cut and are inserted into the exposed parts of the rebates 31, 31 of the post 2 and rail 3 such that the rebates 93 of the infill strip 9 engage the lips 23, 33 of the posts 2 and rails 3. Thus, the posts 2 and rails 3 appear to be shaped as uninterrupted cylindrical members, which provides an improved aesthetic appearance.
A handrail 7 is then secured to the upper part 83 by screws 71 which extend through the holes 832 and are fastened into the handrail 7, as shown in
Successive sections of balustrade 1 can be installed in a similar fashion. The posts 2 have four rebates 21 to accommodate changes in direction, Moreover, the first part 51 of the connector 5 is free to rotate through an angle of 52° when located within the rebate 21 of the post 2, thereby allowing, for example, 45′ turns to be accommodated. A plurality of connectors 5 can be retained within a single rebate 21 of the post 2.
The invention is not limited to the embodiments as shown. For example, other engaging means may be used, the connectors and/or brackets may comprise male parts.
Whilst the connector 5 and baluster bracket 6 in the embodiment described above include elongate engaging members 51, 61 which are substantially cylindrical along their length, albeit interrupted with reinforcement ribs in the case of the baluster bracket 6, it should be appreciated that the brackets may simply include portions thereof. For example, the central portion of the elongate member 61 of the baluster bracket 6 may be omitted, wherein the ends 611, 612 are integrally formed with the mid section 615. The terms elongate member, elongate part and elongate portion should be construed accordingly.
The components may be made from other materials from those listed.
The post may have any number of rebates 21. The, one or each rebate need not extend then entire length of the post 2. The post 2 and base 24 may be formed as two parts and connected together, such as by welding, for supply as a single component. Alternatively, the post and base may be formed as a unitary component.
The fittings used to secure the connector to the post and/or the bracket to the rail may be resiliently urged, they may comprise friction fittings or snap fittings. The connector and/or bracket may be introduced to the rebate in the post and/or rail, or engaged with other portion, in a direction which is not along the principal axis of post and/or rail. Alternatively, the connector and/or bracket may comprise a securing means which includes an expansion fitting arranged to be contractable to engage the post and/or rail.
Moreover, whilst the expansion fittings 513, 514, 613a, 614a, 613b, 614b of the connector 5 and baluster bracket 6 designs described above are configured to receive grub screws therein to effect the expansion thereof, several alternatives are envisaged. For instance, the threaded surfaces may be replaced by substantially smooth or roughened surfaces to frictionally engage a member to be inserted therein. Additionally or alternatively, a tapered shaft with a bayonet type engaging means is envisaged without departing from the scope of the invention.
The rail may comprise, or have secured thereto, means to restrict pivotal movement of a baluster bracket secured thereto, in addition or as an alternative to those of the bracket. Such means may be attached to the bracket if not formed or joined therewith.
| Number | Date | Country | Kind |
|---|---|---|---|
| 0603645.3 | Feb 2006 | GB | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/GB2007/000642 | 2/23/2007 | WO | 00 | 12/11/2008 |
