Embodiments of the present disclosure generally relate to a railing system having a plurality of balusters connected to one or more rails. In particular, embodiments relate to a railing system having a clip with spring action to couple at least one baluster to a rail of the railing system.
Railing systems are used extensively for a variety of functional purposes, for example, as fencing to secure people, animals, and land, and to prevent entry into or exit from a specified area. Railing systems also may have aesthetic purposes, for example, on decks and around yards, stairway, terraces, and gardens. Railing systems often include at least one horizontal rail affixed to at least one vertical post, and optionally a plurality of balusters.
Consumers often have a preference regarding aesthetic features, such as color of a rail or a rail topper, apparent texture (e.g., matte, faux wood, etc.), shape, materials (e.g. vinyl, wood, iron, metal, etc.), etc. Stocking all possible combinations of aesthetic features that a manufacturer offers may be expensive for a retailer. Balusters that rest insecurely within their rails do not provide a desired aesthetic to consumers, and may be unsafe.
Railing systems generally may include a bottom rail, a top rail and pickets (e.g., balusters) mounted vertically therebetween. The top and bottom rails may include hor-izontally extending sections and angled sections, such as for steps or inclined ground. Typically, apertures are cut into the opposing surfaces of the bottom rail and top rail so as to receive ends of the pickets. The installer must estimate the size of the aperture to be cut into the rails, which may be not only be time consuming and inefficient, but also difficult if the pickets are installed at an angle to the rail. Also, because of cutting toler-ances, the pickets may not be tightly received in the railing and resulting in a less dura-ble, weaker railing system than if there were a tight fit. Further, the pickets have portions extending into the rails and thus, are longer than what is actually needed, resulting in added shipping costs and material costs.
For the foregoing reasons, there is a need for an apparatus that will allow for an efficient assembly of horizontal and angled sections of railing systems. There is a further a need for an apparatus that is aesthetic pleasing, and enhances the strength and durability of such structures while reducing shipping and material costs.
Embodiments disclosed herein relates to a clip for coupling a baluster to a rail of a railing system. More specifically, the embodiments disclose herein relates to a clip that enables both a vertical orientation and an angular orientation of the baluster relative to the rail.
The railing system, as disclosed by the present disclosure, can be advantageously combined with the traditional railing system to offer a completely different look to the railing. Multiple styles may be offered for sale by a retailer, without devoting separate bay space to each possible combination of rail and deck board topping. The railing system can be retrofitted with existing railings purchased previously by customers. Once installed, the railing system provides secure attachment of rails to the balusters.
As disclosed by the present disclosure, the railing system may include an elongated rail with a plurality of apertures. The railing system also includes a plurality of clips configured to be inserted within the plurality of apertures, those apertures having a ridge that secures the clip to the rail. The clip includes a spring portion configured to fixedly attach the clip to the rail. The clips are further configured to couple a plurality of balusters to the elongated rail.
Embodiments, in accordance with the present invention, are directed to a railing system. The railing system includes an upper rail comprising a planar surface. The planar surface of the upper rail includes a plurality of apertures. The railing system also includes a lower rail spaced from the upper rail and comprising a planar surface. The planar surface of the lower rail also includes a plurality of apertures. The railing system further includes a plurality of balusters positioned between the upper rail and the lower rail. The railing system also includes a clip configured to attach one baluster of the plurality of balusters to the lower rail or the upper rail. The clip includes a baluster engagement portion configured to be received within an open end of the one baluster. The baluster engagement portion is configured to be seated on the planar surface of the lower rail or the upper rail. The clip also includes a tab extending from the baluster engagement portion. The tab includes a fin portion configured to be inserted within one aperture of the plurality of apertures of the upper rail or the lower rail. Further, the fin portion has a first end surface and a second end surface opposite to the first end surface. The first end surface has a curvilinear shape to allow rotation of the clip between a first position and a second position relative to the upper rail or the lower rail. The tab also includes a spring portion coupled to the fin portion. The spring portion extends partially between the first end surface and the second end surface so that the clip is rotatable between the first position and the second position. Further, the spring portion is configured to secure the clip to the upper rail or the lower rail upon insertion of the fin portion by at least a predetermined distance within the one aperture.
Embodiments in accordance with the present invention are further directed to a railing system. The railing system includes a rail comprising a planar surface. The planar surface of the rail includes at least one aperture. The railing system also includes a clip configured to attach a baluster to the rail. The clip includes a baluster engagement portion configured to be received within an open end of the baluster. The baluster engagement portion is configured to be seated on the planar surface of the rail. The clip also includes a tab extending from the baluster engagement portion. The tab includes a fin portion configured to be inserted within the at least one aperture of the rail. The fin portion has a first end surface and a second end surface opposite to the first end surface. The first end surface has a curvilinear shape to allow rotation of the clip between a first position and a second position relative to the rail. The tab also includes a spring portion coupled to the fin portion. The spring portion extends partially between the first end surface and the second end surface so that the clip is rotatable between the first position and the second position. Further, the spring portion is configured to secure the clip to the rail upon insertion of the fin portion by at least a predetermined distance within the at least one aperture.
Embodiments in accordance with the present invention further provide a clip for attaching a baluster to a rail. The clip includes a baluster engagement portion configured to be received within an open end of the baluster. The baluster engagement portion includes a mounting surface configured to be seated on a planar surface of the rail. The clip also includes a tab extending from the baluster engagement portion. The tab includes a fin portion configured to be inserted within an aperture of the rail. The fin portion has a first end surface and a second end surface opposite to the first end surface. Further, the first end surface has a curvilinear shape to allow rotation of the clip between a first position and a second position relative to the rail. The tab also includes a spring portion coupled to the fin portion. The spring portion extends partially between the first end surface and the second end surface so that the clip is rotatable between the first position and the second position. The spring portion is configured to secure the clip to the rail upon insertion of the fin portion by at least a predetermined distance within the aperture.
Embodiments of the present disclosure may provide several advantages depending on their configuration. It is an object of the present disclosure to provide a railing system, a railing kit, a method for assembling the railing system, which simplify an on-site assembly of a railing, enhance safety during the on-site assembly, and improve the aesthetic appeal of the railing in the assembled state.
These and other advantages will be apparent from the present application of the embodiments described herein.
The preceding is a simplified summary to provide an understanding of some embodiments of the present disclosure. This summary is neither an extensive nor exhaustive overview of the present disclosure and its various embodiments. The summary presents selected concepts of the embodiments of the present disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
The foregoing and other aspects of the embodiments disclosed herein are best understood from the following detailed description when read in connection with the accompanying drawings. For the purpose of illustrating the embodiments disclosed herein, there is shown in the drawings embodiments that are presently preferred, it being understood, however, that the embodiments disclosed herein are not limited to the specific instrumentalities disclosed. Included in the drawings are the following figures:
While embodiments of the present disclosure are described herein by way of example using several illustrative drawings, those skilled in the art will recognize the present disclosure is not limited to the embodiments or drawings described. It should be understood the drawings and the detailed description thereto are not intended to limit the present disclosure to the particular form disclosed, but to the contrary, the present disclosure is to cover all modification, equivalents, and alternatives falling within the spirit and scope of embodiments of the present disclosure as defined by the appended claims.
The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.
Embodiments of the present disclosure will be described below in conjunction with exemplary railing systems. Those skilled in the art will recognize the disclosed techniques may be used in building any railing that may be aesthetically pleasing.
The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
The pair of posts 101 may be anchored to a solid surface, such as a side of a building, or may be sunk into a ground surface “S”, or bolted to a flooring for support. In an exemplary embodiment, the pair of posts 101 may be flush on the ground surface “S” and supported by a post base 109. Further, the posts 101 are substantially stationary with respect to the ground surface “S”. Each of the posts 101 may have a hollow elongate structure having a longitudinal major axis “L”. Each of the posts 101 may further include a top longitudinal opening (not shown in
Further, a pair of mounts (not shown in
The upper rail 103 and the lower rail 105 extend between the posts 101 and are spaced apart along the longitudinal axis “L”. The upper rail 103 and the lower rail 105 extend along a transverse axis “T”, which is substantially perpendicular to the longitudinal axis “L”. Further, each of the upper rail 103 and the lower rail 105 may have a planar surface (not shown in
The railing system 100 further includes a plurality of clips (not shown in
The balusters 107 are disposed between and coupled to the upper rail 103 and the lower rail 105. In some embodiments, the balusters 107 are coupled to the upper rail 103 and the lower rail 105 through the plurality of clips. In a further embodiment, one or more U-channels (not shown) also may be provided on the posts 101 in order to couple the posts 101 to adjacent balusters 107. The balusters 107 may have a closed top, an open top, or a lattice top. Each of the balusters 107 may have a substantially flat hollow structure. Further, the balusters 107 may have any suitable cross-section, for example, but not limited to, rectangular, square, polygonal, oval, circular, elliptical, and so forth. In an alternate embodiment, an adapter rail also may be coupled to the upper rail 103 and/or the lower rail 105 to support the balusters 107.
In some embodiments, the pair of posts 101, the upper rail 103, the lower rail 105 and the plurality of balusters 107 may be made of various materials such as, but not limited to, a composite material, aluminum, plastics, acrylics, glass, and so forth. Further, various techniques may be used to manufacture the components of the railing system 100 such as, but not limited to, extrusion, molding, casting, machining, and so forth.
Each of the upper rail 203 and the lower rail 205 may include a planar surface (not shown in
In some embodiments, the railing systems 100, 200 also may include interior chases or passages for installation of wires, cables and the like.
The components of the railing system 100 and 200 may be part of a kit that is assembled on-site. The railing system 100, 200, as described above, are purely exemplary in nature, and various alternatives can be envisioned within the scope of the present disclosure.
Each of the pair of the posts 301 may have a hollow elongate structure having the longitudinal major axis “L”. Each of the posts 301 may further include a top longitudinal opening 301c, which a closed by a cap 311. In some embodiments, the cap 311 is configured to be coupled to the post 301 through friction fit. In some other embodiments, the cap 311 is configured to be coupled to the post 301 by any suitable fastening method, such as, but not limited to, an adhesive, one or more mechanical fasteners, or a combination thereof.
In some embodiments, the railing system 300 also includes a pair of post bases 309. The post bases 309 support the corresponding posts 301 on the ground surface “S”. The post bases 309 also may be partially embedded within the ground. Further, the post bases 309 enable the posts 301 to remain substantially stationary with respect to the ground surface “S”.
The pair of upper mounts 313 and the pair of lower mounts 315 are configured to be coupled to the respective posts 301. Each of the upper mounts 313 is positioned proximate to a top end 301a of the respective posts 301, while each of the lower mounts 315 is spaced apart from the corresponding upper mounts 313 and is positioned proximate to a bottom end 301b of the respective posts 301. Further, the upper mounts 313 and the lower mounts 315 are configured to support the upper rail 303 and the lower rail 305, respectively, between the posts 301. The upper mounts 313 and the lower mounts 315 may be coupled to the posts 101 via one or more mechanical fasteners, an adhesive, a mechanical joint or a combination thereof. Alternatively, the upper mounts 313 and the lower mounts 315 may be coupled to the posts 301 by various methods such as, but not limited to, welding, brazing, and the like.
The upper rail 303 and the lower rail 305 are configured to be disposed between and coupled to the pair of posts 301. The upper rail 303 and the lower rail 305 are supported by the upper mounts 313 and the lower mounts 315, respectively. Further, the upper rail 303 and the lower rail 305 may be coupled to the upper mounts 313 and the lower mounts 315, respectively, through friction fit, an adhesive or a combination thereof. Further, each of the upper rail 303 and the lower rail 305 may include a plurality of apertures (not shown in
The clips 317 are further configured to attach the plurality of balusters 307 to the upper rail 303 and the lower rail 305. The clips 317 are configured to be attached to the plurality of the balusters 307 through friction fit, an adhesive, a mechanical joint, mechanical fasteners, or a combination thereof. In an alternative embodiment, the clips 317 enable the balusters 307 to be positioned at a plurality of angular orientations relative to the upper rail 303 and the lower rail 305. In some embodiments, the clips 317 may be manufactured from various materials such as, but not limited to, plastic, glass, metal, metallic alloys, acrylics, a composite material, and so forth. Further, the plurality of clips 317 may be manufactured using various techniques such as, but not limited to, molding, extrusion, casting, machining, and so forth.
The balusters 307 may have a closed top, an open top or a lattice top. Each of the balusters 307 may have substantially flat hollow structures. Further, the balusters 307 may have any suitable cross-section, for example, but not limited to, rectangular, square, polygonal, oval, circular, elliptical, and so forth. The balusters 307 may abut with each other or a clearance may be provided between them.
Various components of the railing system 300 may facilitate the installation of railing system 300 at a plurality of angular orientations, such as installation at level-railing, installation at non-level or angular railing and so forth. Further, level-railing installation is when the angle of installation of a railing system is approximately zero with reference to the installation surface. Moreover, non-level or angular railing is when the angle of a railing system is greater than zero such as, in case of a staircase railing.
As illustrated in
The baluster engagement portion 641 also includes a pair of support portions 645. The support portion 645 includes a first support surface 647 configured to support the baluster engagement portion 641 on the planar surface 421. The support portion 645 also includes a second support surface 649 extending from the first support surface 647. The second support surface 649 is inclined with respect to the first support surface 647. In the illustrated embodiment, the second support surface 649 is inclined at an angle “a1” with respect to the first support surface 647. In an embodiment, the angle “a1” may lie in a range from about 29 degrees to 41 degrees relative to the rail 400. Further, each of the first support surface 647 and the second support surface 649 is substantially planar. In other embodiments, at least one of the first support surface 647 and the second support surface 649 may be curved. In some embodiments, the support portions 645 are configured to be flush with the pair of side walls 535 of the baluster 500. Further, each of the support portions 645 may have a variable length and width throughout. In the illustrated embodiment, the support portion 645 has a maximum width “w6”. Further, the maximum width “w6” is less than or approximately equal to the height “h3” of the baluster 500 such that the baluster engagement portion 641 can be completely inserted within the baluster 500. In some other embodiments, each of the support portions 645 may include multiple ribs that interface with the pair of side walls 535 of the baluster 500 to improve coupling between the baluster engagement portion 641 and the baluster 500.
The baluster engagement portion 641 further includes recesses 651 between the mounting surface 643 and each of the support portions 645. Multiple recesses may be used, in accordance with the geometry of baluster 500. The recesses 651 may allow ex-pansion or contraction of the support portions 645 or the mounting surface 643 that may occur due to temperature change. In some other embodiments, recesses 651 may allow flexing of the support portion 645 during the insertion of baluster engagement portion 641 into one of open ends 537 of baluster 500. In some embodiments, recesses 651 allow clip 600 to be wider than a respective opening in baluster 500, and permit tips of support portions 645 to flex inward during insertion. This creates a preload condition with interference (e.g., a mechanical stop) between clip 600 and baluster 500, thus providing precise placement as well as maintaining location during curing if an adhesive or other permanent fastening method had been used. Preloading also compensates for variation in opening dimensions of baluster 500, and allows installation of a rail (e.g., rail 400) without clip 600 disengaging from baluster 500 if clip 600 had not been secured perma-nently to baluster 500.
The clip 600 includes a tab 653 extending from the baluster engagement portion 641. In an embodiment, the tab 653 extends by a length “l7” from the mounting surface 643. The tab 653 includes a fin portion 655 that is configured to be inserted within one of the plurality of apertures 427. In some embodiments, the mounting surface 643 may prevent the insertion of the clip 600 into the aperture 427 beyond the tab 653. Specifically, the width “w5” of the mounting surface 643 is greater than the width “w1” of each of the apertures 427. Therefore, upon insertion of the tab 653 into the aperture 427 to a predetermined distance, the mounting surface 643 rests on the planar surface 421 and prevents further insertion of the clip 600 within the aperture 427. The predetermined distance may be less than or equal to the height “h2” of rail 400. Further, the predetermined distance may be substantially equal to the length “l7” of the tab 653. As such, the mounting surface 643 enables the baluster engagement portion 641 to be disposed on the planar surface 421 once the tab 653 is completely inserted within the rail 400. In some embodiments, the mounting surface 643 may support the clip 600 on the planar surface 421.
As illustrated in
The tab 653 may have variable width as the spring portion 657 has a curvilinear shape. Specifically, the spring portion 657 may curve away from the fin portion 655. In some embodiments, the spring portion 657 deforms (i.e., flexes) to provide a uniform thickness “t7” to the tab 653. The uniform thickness “t7” is less than or approximately equal to the width “w1” of the aperture 427 (as shown in
Further, the fin portion 655 includes an upper part 656a located adjacent to the mounting surface 643, a middle part 656b extending from the upper part 656a and a lower part 656c extending from the middle part 656b. A maximum thickness of the lower part 656c may be substantially equal to the uniform thickness “t7”. Further, a thickness of the upper part 656a may be substantially equal to the width of the lower part 656c, i.e., the uniform thickness “t7”. Therefore, the upper and lower parts 656a, 656b may be inserted within the aperture 427. Therefore, the spring portion 657 may prevent removal of the clip 600 from the aperture 427, thereby securing the clip 600 to the rail 400 as the uniform thickness “t7” is less than or approximately equal to the width “w1” of the aperture 427. The upper part 656a may have substantially planar edges along a length, and curved edges at both ends. Further, the lower part 656c may have a rounded end. The spring portion 657 extends from an upper surface of the lower part 656c towards the upper part 656a. In the illustrated embodiment, an upper edge 657a of the spring portion 657 is located at a distance “l8” relative to a bottom surface of the tab 653. In an embodiment, a difference between the length “l7” of the tab 653 and the distance “l8” may be less than or equal to the thickness “t2” of the wall 420 of the rail 400 (shown in
Further, the middle part 656b has a curvilinear shape in order to accommodate the spring portion 657. Specifically, middle part 656b surrounds a recess 658 so that the spring portion 657 can move between the normal state and a deformed state.
The clip 600 may be formed by various manufacturing methods, such as molding, casting, machining, or a combination thereof. Various sections (for example, the baluster engagement portion 641, the fin portion 655, and the spring portion 657) of the clip 600 may be integrally formed, or can be manufactured separately and then assembled together.
The clip 700 includes a tab 753 extending from the baluster engagement portion 741. The tab 753 includes a fin portion 755 that is configured to be inserted within one of the plurality of apertures 427 (shown in
In some embodiments, the baluster engagement portion 741 includes ribs 759 to impart strength and rigidity to the clip 700. Further, the baluster engagement portion 741 may include an upper portion 760 that may facilitate manual handing of the clip 700 during engagement with the rail 400 and rotation of the clip 700 relative to the rail 400. The upper portion 760 may be have a substantially rectangular cross-section with curved edges.
The clip 1217 further includes a tab 1253 extending from the baluster engagement portion 1241. The tab 1253 includes a fin portion 1255 and a spring portion 1257 coupled to the fin portion 1255. As illustrated in
The clip 1317 further includes a tab 1353 extending from the baluster engagement portion 1341. The tab 1353 includes a fin portion 1355. The fin portion 1355 has a first end surface 1355a and a second end surface 1355b opposite to the first end surface 1355a. In an exemplary embodiment, the first end surface 1355a has a curvilinear shape to allow rotation of the clip 1317 between a first position and a second position relative to the planar surface 1321. Further, the tab 1353 may have a variable width due to the curvilinear shape of the first end surface 1355a. However, the tab may have a maximum width “w11” proximate to the baluster engagement portion 1341 and a minimum width “w12” distal to the baluster engagement portion 1341. Further, the maximum width “w11” of the tab 1353 is less than or approximately equal to the length “l1” (shown in
Though the above embodiments are described with reference to a railing system and assembly, embodiments of the present disclosure are intended to cover any railing system having one or more rails with clips to couple one or more balusters. The clips may be easily coupled with corresponding rails, thereby enabling quick and simple assembly of the railing system.
The railing system, as disclosed by the present disclosure, can be advantageously combined or retrofitted with an existing railing system. A user can easily couple a baluster to a rail using a clip of the present disclosure. Further, the clip allows the coupling of the baluster and the rail for any railing system such as, but not limited to, a leveled railing system, an angled railing system, and so forth. Therefore, the user can assemble the railing system as per his or her preferences. Further, the baluster is not required to have an extra length to be inserted within the rail, which reduces overall cost of the railing system as well as shipping costs.
Although the invention has been described with reference to exemplary embodiments, it is not limited thereto. Those skilled in the art will appreciate that numerous changes and modifications may be made to the preferred embodiments of the invention and that such changes and modifications may be made without departing from the true spirit of the invention. It is therefore intended that the appended claims be construed to cover all such equivalent variations as fall within the true spirit and scope of the invention.
The exemplary embodiments of this present invention have been described in relation to a railing system. However, to avoid unnecessarily obscuring the present invention, the preceding description omits a number of known structures and devices. This omission is not to be construed as a limitation of the scope of the present invention. Specific details are set forth by use of the embodiments to provide an understanding of the present invention. It should however be appreciated that the present invention may be practiced in a variety of ways beyond the specific embodiments set forth herein.
A number of variations and modifications of the present invention can be used. It would be possible to provide for some features of the present invention without providing others.
The present invention, in various embodiments, configurations, and aspects, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, configurations, and aspects, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments, configurations, or aspects hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.
The foregoing discussion of the present invention has been presented for purposes of illustration and description. It is not intended to limit the present invention to the form or forms disclosed herein. In the foregoing Detailed Description, for example, various features of the present invention are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention the present invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of the present invention.
Moreover, though the description of the present invention has included description of one or more embodiments, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the present invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights that include alternative embodiments, configurations, or aspects to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
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