FIELD
The disclosure relates to railing assemblies in which one or more balusters are pivotably mounted between a pair of rails. Specifically, the disclosure relates to such railing assemblies that are fabricated from plastic.
INTRODUCTION
The following is not an admission that anything discussed below is prior art or part of the common general knowledge of persons skilled in the art.
U.S. Pat. No. 3,414,236 (Siegal) purports to disclose a foldable hand rail in the form of a downwardly opening channel having side walls diverging at their lower ends, the insides of which form wedging surfaces. The diverging side walls engage outwardly extending feet of an inner channel, pivoted to the pickets of the hand rail. Means located between the pickets are provided to draw the hand rail toward the channel and wedge the channel into clamping engagement with the pickets by wedging movement of the diverging side walls of the rail along the outwardly extending feet of the inner channel, to thereby provide a rigid hand rail structure free from rattling.
U.S. Pat. No. 3,804,374 (Thom) purports to disclose a handrail structure which has pairs of laterally spaced post members capable of being arranged to present a variety of eye-appealing appearances including a combination of wood and metal. Each pair of posts has vertically adjustable clamp mechanisms extending laterally therebetween and in gripping complemental engagement to rigidly hold the pair of posts in laterally spaced relationship and to define a space between the posts for receiving wood filler pieces. Both the posts and the clamp mechanisms are cut from extruded metal pieces for inexpensive manufacture. An offset handrail is angularly adjustably mountable upon one of the clamp mechanisms of each pair of posts.
U.S. Pat. No. 4,272,061 (Suckno) purports to disclose a system comprising a hand rail and shoe rail having channels running longitudinally therein. A plurality of balusters are connected between the hand rail and shoe rail by means of pivot pins extending through the walls of the channel and a hole formed in each baluster. In this manner, the pitch of the baluster with respect to the hand rail and the shoe rail can be changed to accommodate the pitch of the staircase upon which the system is to be used. Once installed, the channel areas between adjacent balusters are filled and the hand rail and shoe rail is attached to a newel post.
SUMMARY
The following summary is provided to introduce the reader to the more detailed discussion to follow. The summary is not intended to limit or define the claims.
According to one aspect, a railing assembly comprises an upper rail and an opposed lower rail. Each rail comprises a top surface and an opposed bottom surface. An upper standoff is mounted to the bottom surface of the upper rail, and a lower standoff mounted to the top surface of the lower rail. The railing assembly further comprises a baluster. The baluster comprises a top end portion and an opposed bottom end portion. The top end portion is pivotably mounted to the upper standoff about a generally horizontal upper pivot axis, and the bottom end portion is pivotably mounted to the lower standoff about a generally horizontal lower pivot axis.
In some examples, the railing assembly further comprises a top baluster connector mounted to the top end portion, and a bottom baluster connector mounted to the bottom end portion. The upper standoff may be pivotably mounted to the top baluster connector, and the lower standoff may be pivotably mounted to the bottom baluster connector. The top baluster connector and the bottom baluster connector may each comprise a baluster connector hub and a baluster connector arm. Each baluster connector hub may be pivotably mounted to one of the standoffs, and each baluster connector arm may be inserted into the baluster.
In some examples, the upper and lower standoffs each comprise a standoff base and a standoff hub. Each standoff hub may be pivotably mounted to one of the baluster connector hubs, and each standoff base may be mounted to one of the rails. A pivot pin may mount each standoff hub and baluster connector hub together. The pivot pin may be integrally formed with one of the baluster connector hub and the standoff hub.
In some examples, the upper standoff and the lower standoff may each comprise two generally horizontally spaced apart standoff portions. Each standoff portion may comprise a standoff base portion and a standoff hub portion. For each of the upper standoff and lower standoff, the standoff base portions may be mounted together, and the standoff hub portions may be spaced apart and a gap may be therebetween. The top baluster connector and bottom baluster connector may each comprise a baluster connector hub, and each baluster connector hub may be received in one of the gaps and pivotably mounted to the respective standoff hub portions.
In some examples, each rail may include a longitudinally extending outer rail portion and longitudinally extending inner rail portion. The upper standoff and lower standoff may be mounted to the respective inner portions by a fastener.
In some examples, the upper rail, lower rail, and baluster may be provided in a common plane.
In some examples, each of the lower standoff and upper standoff may have an abutment surface. Each abutment surface may abut one of top surface and the bottom surface.
According to another aspect, a railing assembly comprises an upper rail and an opposed lower rail. An upper rail connector is mounted to the upper rail, and a lower rail connector is mounted to the lower rail. The railing assembly further comprises a baluster comprising a top end portion, and an opposed bottom end portion. A top baluster connector is mounted to the top end portion, and a bottom baluster connector is mounted to the bottom end portion. The upper rail connector is pivotably mounted to the top baluster connector about a generally horizontal upper pivot axis, and the lower rail connector is pivotably mounted to the bottom baluster connector about a generally horizontal lower pivot axis.
In some examples, the top baluster connector and the bottom baluster connector may each comprise a baluster connector hub and a baluster connector arm. Each baluster connector hub may be pivotably mounted to one of the rail connectors, and each baluster connector arm may be inserted into the baluster. The upper rail connector and lower rail connector may each comprise a rail connector base and a rail connector hub. Each rail connector hub may be pivotably mounted to one of the baluster connector hubs, and each rail connector base may be mounted to one of the rails. A pivot pin may mount each rail connector hub to each baluster connector hub. Each pivot pin may be integrally formed with one of the baluster connector hubs and rail connector hubs.
In some examples, the upper rail and lower rail may each comprise a top surface and an opposed bottom surface. The upper rail connector may be mounted to the bottom surface of the upper rail, and the lower rail connector may be mounted to the top surface of the lower rail.
The upper rail connector and the lower rail connector may each comprise two generally horizontally spaced apart rail connector portions. Each rail connector portion may comprise a rail connector base portion and a rail connector hub portion. For each of the upper rail connector and lower rail connector, the rail connector base portions may be mounted together, and the rail connector hub portions may be spaced apart and a gap may be therebetween. The top baluster connector and bottom baluster connector may each comprise a baluster connector hub. Each baluster connector hub may be received in one of the gaps and may be pivotably mounted to the respective rail connector hub portions.
In some examples, each rail may include a longitudinally extending outer portion and longitudinally extending inner portion. The upper rail connector and lower rail connector may be mounted to the respective inner portion by a fastener.
In some examples, the upper rail, lower rail, and baluster may be provided in a common plane.
In some examples, each of the lower rail connector and upper rail connector has an abutment surface. Each abutment surface may abut one of top surface and the bottom surface.
In some examples, the baluster may be an extruded vinyl lineal. The upper rail connector, lower rail connector, upper baluster connector, and lower baluster connector may be fabricated by injection molding of a plastic.
DRAWINGS
The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:
FIG. 1 is a perspective view of an exemplary railing assembly, viewed from a first side;
FIG. 2 is a perspective view of a portion of the railing assembly of FIG. 1, viewed from a second side;
FIG. 2B is a cross sectional view of the railing assembly of FIG. 1, taken vertically through a baluster, where the baluster extends perpendicular to the upper rail and lower rail;
FIG. 3 is a perspective view of a rail connector of the railing assembly of FIG. 1;
FIG. 4 is a perspective view of a baluster connector of the railing assembly of FIG. 1;
FIG. 5 is an exploded perspective view of the rail connector of FIG. 3 and the baluster connector of FIG. 4;
FIG. 6 is an exploded perspective view of an alternate exemplary rail connector and an alternate exemplary baluster connector;
FIG. 7 is a perspective view of an alternate exemplary railing assembly;
FIG. 8 is an exploded perspective view of the rail connector and baluster connector of FIG. 8;
FIG. 9 is a perspective view of the rail connector and baluster connector of FIG. 7 in an assembled configuration, showing an alternate angular configuration in dotted line;
FIG. 10 is a perspective view of a rail connector portion of the rail connector of FIG. 7;
FIG. 11 is a cross sectional view of the rail connector portion of FIG. 10, taken along line 11-11; and
FIG. 12 is a cross sectional view of the railing assembly of Figure t, taken vertically through a baluster, where the baluster extends perpendicular to the upper rail and lower rail.
DETAILED DESCRIPTION
Various apparatuses or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover processes or apparatuses that differ from those described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any exclusive right granted by issuance of this patent application. Any invention disclosed in an apparatus or process described below and for which an exclusive right is not granted by issuance of this patent application may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.
Referring to FIG. 1, an exemplary railing assembly 100 is shown. The railing assembly 100 includes a pair of rails, including an upper rail 102, and a lower rail 104. A plurality of balusters 106 are mounted between the upper rail 102 and lower rail 104. In the example shown, the balusters 106 are pivotably mounted between the upper rail 102 and lower rail 104. This can allow the angle of the balusters 106 with respect to the upper rail 102 and lower rail 104 to be adjusted. For example, the railing assembly 100 may be pre-assembled and then subsequently installed in a variety of configurations, in which the balusters are generally vertical, and the rails 102, 104 are generally horizontal (for installation on, for example, porches or balconies), or in which the rails are at an incline relative to the horizontal (for installation, for example, on staircases of various pitches).
Referring to FIGS. 1 and 2, in the example shown, the railing assembly 100 includes a plurality of pivot joints 107 for connecting the balusters 106 to the rail 102, 104. The pivot joints 107 include baluster connectors 108 affixed to the balusters 106 and rail connectors 118 affixed to the rails 102, 104. In the example illustrated, the pivot joints 107 include upper pivot joints 107a having top baluster connectors 110 (of the baluster connectors 108) affixed to an upper end of the balusters 106, and upper rail connectors 120 (of the rail connectors 118) attached to the upper rail 102. The pivot joints 107 further include lower pivot joints 107b having bottom baluster connectors 112 (of the baluster connectors 108) affixed to lower ends of the balusters 106 and lower rail connectors 122 (of the rail connectors 118) attached to the lower rail 104. The top baluster connectors 110 are pivotably mounted to the upper rail connectors 120, and the bottom baluster connectors 112 are pivotably mounted to the lower rail connectors 122, in order to pivotably mount the balusters 106 between the upper rail 102 and lower rail 104.
In the example shown, each baluster 106 includes a top end portion 114, and an opposed bottom end portion 116. One top baluster connector 110 is mounted to the top end portion 114 of each baluster 106, and one bottom baluster connector 112 is mounted to the bottom end portion 116 of each baluster 106. In the example shown, the upper rail 102 and lower rail 104 each include a top surface 128, and an opposed bottom surface 130. The upper rail connectors 120 are mounted to the bottom surface 130 of the upper rail 102, and the lower rail connectors 122 are mounted to the top surface 128 of the lower rail 104. As will be described in further detail below, each upper rail connector 120 is pivotably mounted to one top baluster connector 110 about a generally horizontal upper pivot axis 121(shown in FIG. 2B), and each lower rail connector 122 is pivotably mounted to one bottom baluster connector 112 about a generally horizontal lower pivot axis 123 (shown in FIGS. 2 and 2B), in order to allow the balusters 106 to pivot with respect to the upper rail 102 and lower rail 104.
Referring to FIGS. 2 and 2B, in the example shown, the upper rail connectors 120 and lower rail connectors 122 space the balusters 106, as well as the baluster connectors 108, away from the upper rail 102 and lower rail 104, and may also be referred to as upper standoffs 120 and lower standoffs 122, respectively. More specifically, in the example shown, the upper rail connectors 120 and lower rail connectors 122 space the upper pivot axis 121 and lower pivot axis 123 away from the upper rail 102 and lower rail 104, respectively, by an offset distance 125, 127, respectively.
Referring still to FIG. 2B, in the example shown, the upper rail 102, lower rail 104, and balusters 106 are all provided in a common vertical plane. In other words, the balusters 106 are generally laterally aligned (i.e. aligned in a generally horizontal direction) with the upper rail 102 and lower rail 104. The balusters 106 have a bluster thickness measured horizontally and perpendicular to the axes of the rails 102, 104, and the rails have a rail thickness that can be equal to or greater than the baluster thickness. In the example illustrated, the rail thickness is greater than the baluster thickness, and the baluster thickness is disposed entirely within the lateral extend of the rail thickness. In this configuration, the balusters avoid being laterally offset with respect to the upper rail 102 or lower rail 104.
Referring to FIG. 3, each rail connector 118 includes a rail connector base 132 (also referred to as a standoff base 132), and a rail connector hub 134 (also referred to as a standoff hub 134). The rail connectors 118 are mounted to the rails 102, 104 via the rail connector bases 132, and are mounted to the baluster connectors 108 via the rail connector hubs 134. Each rail connector base 132 includes a generally planar abutment surface 136, which abuts either the top surface 128 of the lower rail 104 or the bottom surface 130 of the upper rail 102. Each rail connector base 132 further includes a pair of screw bosses 138 integrally formed therein. Fasteners, such as screws 139 (FIG. 2B), may be passed through either the top surface 128 or the bottom surface 130 of the rails and into the screw bosses 138, to secure the rail connectors 118 to the lower rail 104 or upper rail 102, respectively. In the example shown, the upper rail 102 and lower rail 104 are each a two-piece assembly (See FIG. 2), and each includes a longitudinally extending inner rail portion 140 (also referred to as beam 140) and a longitudinally extending outer rail portion 142 (also referred to as cover 142). The rail connectors 118 may be secured to the inner rail portions 140 prior to the assembly of the covers 142 to the beams 140.
Referring still to FIG. 3, each rail connector base 132 has a base length 133. The base length defines the distance by which the baluster connectors 108 are spaced away from the upper rail 102 and lower rail.
Referring still to FIG. 3, as mentioned above, the baluster connectors 108 are pivotably connected to the rail connectors 118 via the rail connector hubs 134. In the example shown, each rail connector hub 134 includes a generally rounded projection extending from the rail connector base 132. Each rail connector hub 134 is laterally positioned to one side of the rail connector base 132. A socket 144 is formed generally centrally within each rail connector hub 134. As will be described in further detail below, a pivot pin is mountable in each socket, and the baluster connectors are mounted to the rail connector hubs 134 via the pivot pins, and are pivotable about the pivot pins such that the angle of the balusters 106 with respect to the upper rail 102 and lower rail 104 may be adjusted.
Referring now to FIG. 4, each baluster connector 108 includes a baluster connector arm 146, and a baluster connector hub 148. The baluster connectors 108 are mounted to the balusters 106 via the baluster connector arms 146. Each baluster 106 is generally hollow, and each baluster connector arm is inserted into and frictionally secured within one of the balusters 106.
Referring still to FIG. 4, the baluster connector hubs 148 are mounted to the rail connector hubs 134, to mount the baluster connectors 108 and rail connectors 118 together. Each baluster connector hub 148 includes a generally rounded projection extending from the baluster connector arm 146. Each baluster connector hub 148 is laterally positioned to one side of the baluster connector arm 146. A pivot pin 150 is integrally formed with the baluster connector hub 148. Referring to FIG. 5, when assembled, each baluster connector hub 148 is positioned in facing relation with one of the rail connector hubs 134. Further, the pivot pin 150 is pivotably mounted within the socket 144 of the rail connector hub 134, to mount each baluster connector hub to each rail connector hub. Each pivot pin 150 includes a rib 152 extending about the circumference thereof, and each socket 144 includes a recess 154 extending about the circumference thereof. The rib 152 may be snapped into the recess 154, to pivotably mount the baluster connector 108 to the rail connector 118.
Referring to FIG. 6, an alternate example of a pivot joint is shown, having similar features as the pivot joint 107, identified by like reference characters incremented by 500. In the pivot joint 607, the pivot pin 650 is separately formed from the baluster connector 608. In this example, the pivot pin includes a second rib 653, and the baluster connector hub 648 includes a socket 645 having a recess 655, and the second rib 653 may be snapped into the recess 655.
In a further alternate example (not shown), a pivot pin may be integrally formed with the rail connector, rather than the baluster connector.
Referring now to FIGS. 7 to 12, an alternate example of a railing assembly 700 is shown having similar features as the railing assembly 100 identified by like reference characters incremented by 600. The railing assembly 700 includes alternate rail connectors 718 and baluster connectors 708.
Referring to FIGS. 8, 10, and 12 each rail connector 718 includes two generally horizontally spaced apart rail connector portions 756a, 756b, which may be essentially identical (e.g. they may be formed from the same mold). Each rail connector portion 756a, 756b includes a rail connector base portion 732a, 732b, respectively, and a rail connector hub portion 734a, 734b, respectively. The rail connector base portions 732a and 732b may be assembled together. Specifically, each rail connector base portion 732a, 732b includes a projection 764 and a recess 766 (the projection and recess of only the rail connector portion 756a are shown in FIGS. 8 and 10). The projection 764 of the rail connector portion 756a is receivable in the recess of the rail connector portion 756b, and the projection of the rail connector portion 756b is receivable in the recess 766 of the rail connector portion 756a. When the rail connector base portions 732a, 732b are mounted together, the rail connector hub portions 734a, 734b are spaced apart, and a gap is between them. Each rail connector hub portion 734a, 734b includes an integrally formed pivot pin 750 extending towards the gap (only the pivot pin of the rail connector hub portion 734a is shown in FIG. 8).
Referring to FIGS. 10 and 11, the rail connector base portions 732 have a base length 733. The base length 733 in the example of FIGS. 7 to 12 is generally shorter than the base length 133 of the railing assembly 100, and the offset distance 727 is less than the offset distance 127 of the railing assembly 100. This can provide a different appearance to the railing assembly 700.
Referring still to FIGS. 10 and 11, in the example shown, the rail connector portion 756a includes a screw boss 738 integrally formed therein. The screw boss 738 extends through the rail connector base portion 732a and into the rail connector hub portion 734a, past the pivot axis 723. A screw 735 (Shown in FIG. 12) may be inserted in the screw boss 738 to secure the rail connector portion 756a to the lower rail or upper rail. The length of the screw may be selected so that it extends the full length of the screw boss (i.e. so that it extends into the rail connector hub portion 734a, past the pivot axis 723). This may provide increased structural strength to the rail connector portion 756a.
Referring back to FIGS. 8 and 12, the baluster connector 708 includes a baluster connector arm 746, which is essentially identical to the baluster connector arm 146 of FIGS. 1 to 5. The baluster connector hub 748 includes two sockets 744 on opposed sides thereof (only one of the sockets 744 is visible in FIG. 8). In the example shown, the baluster connector hub 748 is centrally located with respect to the baluster connector arm 746.
Referring to FIG. 9, the baluster connector hub 748 is receivable in the gap between the rail connector hub portions 734a, 734b, and the pivot pins 750a, 750b are receivable in the sockets 744. The pivot pins each include ribs 752 that are snapably receivable in recesses 754 of the sockets. The baluster connectors 708 are pivotable about the pivot pins such that the angle of the balusters 706 with respect to the rail connectors 718 may be adjusted.
Referring again to FIG. 12, in the example illustrated, the upper rail 704 has an upper rail thickness extending between laterally opposed upper rail side faces 702a and 702b, and each baluster 706 has laterally opposed baluster side faces 706a and 706b that are positioned laterally inwardly of the upper rail side faces 702a, 702b. In the example illustrated, the lower rail 704 has a lower rail thickness extending between laterally opposed lower rail side faces 704a and 704b, and the laterally opposed baluster side faces 706a and 706b are positioned laterally inwardly of the lower rail side faces 704a, 704b.
In any of the above examples, the various pieces of the railing assemblies 100, 600, 700 may be fabricated from a plastic. For example, the balusters may be an extruded vinyl lineal. Further, the upper rail connectors, lower rail connectors, upper baluster connectors, and lower baluster connectors may be fabricated by injection molding of a plastic.
While the above description provides examples of one or more processes or apparatuses, it will be appreciated that other processes or apparatuses may be within the scope of the accompanying claims.
Patent Application
20140054530
