Patent Application
20110024709
The present invention relates to improvements in stair rail assemblies, and more particularly, to stair rail assemblies which are easy to assemble and suitable for use with a wide array of stair rails.
Stair rail assemblies with irregular, elaborate and complex geometries are increasing popular, especially in new home construction and in remodeling. Many different kinds of stair rail fittings are available for such stair assemblies. Stair rail fittings connect hand rail to hand rail, hand rail to newel post, handrail to wall, even one fitting can connect into another, etc.
Stair rails with complex or custom shapes are often assembled on site—at the house, condominium or business site where the stair rail will actually be used with its corresponding stair case. A significant problem builders of such stair rail assemblies have is difficultly aligning components of the stair rail assemblies together. If the cuts made to the stair rails are not at the needed correct angles, an end of the stair rail will not match up properly with an adjacent element. Since appearance and aesthetics are important here, a stair rail might need to be scrapped rather than installed at the wrong angle.
The stair rail needs to be aligned properly with the top and the bottom and any intermediate turns in the components which make up the stair rail. For example, a stair rail typically is attached to a series of balusters or posts, and the balusters climb at an angle with respect to a floor or horizontal surface. Also, the stair rail has an end which has to meet up with an end on a newel post or on another stair rail. Although the dimensions may be specified in blueprints, actual tolerance variations must be accounted for.
Traditionally assembly occurs in the following manner. A newel post, which is the upright post about which the steps of an angled, curved or circular staircase wind, is set in position, typcially mounted on a floor or landing. Next, a stair rail is held in correct position but not rigidly attached; measured, and cut to length with a straight angled cut to match with the corresponding part (newel post, another stair rail, rosette). While this approximation technique is fine for relatively simple geometries (such as straight stair rails), the more complex contemprorary designs using up easings and other connecting curved stair rails and goosenecks are quite difficult to cut accurately. Even experienced carpenters will have difficultly with the process. If a cut is made at an angle that is an uncorrectable angle (essentially one where the part cannot be re-cut to or sanded to the appropriate length or angle), then the stair rail and/or the fittings such as goosenecks, level quarter turns, up easings, over easings, etc., cannot be used for that stair case. The stair rail or the fittings is scrap (unless it can be used at a different job site). If the stair rail is cut too long, builders have to spend time shaving and sanding down the stair rail to try to get a good fit. This is tedious and time consuming. Also, additional stair rails may be need to be brought to a job site, which increases need for inventory and resulting costs. This is so in part because manufacturers and builders rely on a complex array of stair case styles and components. The stair rail assembly builder or stair rail assembly manufacturer is forced to carry a large inventory of fittings as well as maintain the ability to create rapidly a custom fitting in a variety of popular woods. If the staircase is not built correctly or is not a “standard” or conventional stair case, then a stair builder or installer may have to wait for a substantial period of time for a custom replacement, since most stair parts manufacturers are unable to maintain a complete inventory of all standard fittings of every conceivable wood species. It would be desirable to provide a low cost device which reduces the need for making difficult cuts on stair rail assemblies, especially those having complex geometries.
In accordance with a first aspect, a stair rail assembly and a method of making a stair rail assembly is disclosed. The stair rail assembly comprises a stair rail having a first end and a cross section, a ball having a spherical surface, and a connector having a first surface, a concave surface and a connector cross section which is the same as the cross section of the stair rail. The first end of the stair rail is rigidly attached to the first surface of the connector, the concave surface of the connector is rigidly attached to a segment of the spherical surface of the ball, such that the concave surface is covered by the segment, and the connector is adjustably connected to the ball along any direction.
From the foregoing disclosure and the following more detailed description of various preferred embodiments it will be apparent to those skilled in the art that the present invention provides a significant advance in the technology of stair rail assemblies. Particularly significant in this regard is the potential the invention affords for providing a high quality, low cost stair rail fitting suitable for use with a wide variety of stair rails. Additional features and advantages of various preferred embodiments will be better understood in view of the detailed description provided below.
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the stair rail assembly as disclosed here will be determined in part by the particular intended application and use environment. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to enhance visualization and clear understanding. In particular, thin features may be thickened, for example, for clarity of illustration. All references to direction and position, unless otherwise indicated, refer to the orientation illustrated in the drawings.
It will be apparent to those skilled in the art, that is, to those who have knowledge or experience in this area of technology, that many uses and design variations are possible for the stair rail assembly disclosed here. The following detailed discussion of various alternative features and embodiments will illustrate the general principles of the invention with reference to a stair rail fitting or connector particularly suitable for use with stair rail assemblies having complex curves and abrupt changes in height. Other embodiments suitable for other applications will be apparent to those skilled in the art given the benefit of this disclosure.
Turning now to the drawings,
Optionally a series of balusters 70 (shown in
In accordance with a highly advantageous feature, a connector 30 is positioned between the ball 20 and the stair rail 40. Connector 30 has a first surface 33 and a concave surface 31, as well as a connector cross section which is the same as the cross section of the stair rail 40. The first end 43 of the stair rail is rigidly attached to the first surface 33 of the connector. As shown in
As assembled, the connector 30 is adjustably connected to the ball 20 along any direction. Three axes are provided in
Optionally the stair rail 40, connector 30 and ball 20 are all made of wood. The connector 30 may be connected to the ball 20 in one of numerous ways. For example, a fastener such as dowel pin 25 may be used, a two sided screw, an adhesive, or a combination of a fastener and adhesive. Where a dowel pin is used, opening or hole 32 in the connector 30 and slot or hole in the ball 20, respectively may be provided to receive the dowel pin 25. The stair rail 40 may be independently connected to the connector in a similar manner by one of a dowel pin, adhesive, and a dowel pin and adhesive. Other suitable elements for connecting the stair rail, connector and ball together will be readily apparent to those skilled in the art given the benefit of this disclosure.
Use of connector 30 allows for many different applications. For example,
One method of assembly of the stair rail assembly is as follows; A first ball is positioned in a first position, such as when the ball is a unitary extension of a newel post, the newel post is attached to the floor. Thus the first position is a fixed position. In a similar manner, a second ball may be positioned in a first position. A first connector and a second connector may also be positioned in a first position. Each connector may be attached to the corresponding ball in the manner discussed above. Alternatively, they may be temporarily held in place against the corresponding ball. Either way, a first distance is defined between a first surface of the first connector and a first surface of the second connector. This distance can be measured. Optionally a stair rail fitting may be held up adjacent the connectors for the measurement. Either way, the stair rail is cut to a length corresponding to the distance between the first surface of the first connector and the first surface of the second connector. Once the stair rail is cut to length, it may be attached to the rest of the elements in the manner described above. Variations of this method may be used to assembly stair assemblies incorporating goosenecks, up easings, and the like. Other methods of assembly will be readily apparent to those skilled in the art given the benefit of this disclosure.
From the foregoing disclosure and detailed description of certain preferred embodiments, it will be apparent that various modifications, additions and other alternative embodiments are possible without departing from the true scope and spirit of the invention. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to use the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
