(1) Field of the Invention
The present invention relates generally to stairways and, more particularly, to a stairway system that provides a series of balusters, which include features which align with both the tread and the handrail.
(2) Description of the Prior Art
In stairway systems, the aesthetic aspects of the alignment of features on the baluster with the treads and the handrail were traditionally done through custom carpentry. In such cases, each baluster was custom hand crafted to create the alignment of the bottom features of each baluster with the tread surface while the top feature of each baluster aligned with the slope of the handrail. To accomplish this alignment each baluster component was hand crafted by a craftsman.
Although still possible today, it is prohibitively expensive for most construction and therefore rarely done. To make such features available at a reasonable cost requires the ability to create a system that allows for only the most limited number of balusters to be manufactured and maintained in inventory, which can be selected to achieve the desired alignment between both the tread and the handrail.
To date such a system has eluded the mass manufacturing industry. For example, some systems have been able to align features within a baluster with the handrail or alternatively with the tread; however, none have provided both features without custom manufacturing. In a tapered baluster system having a gradual tapers or small diameters pin tops it may deceptively appear that features have been aligned with both the handrail and the tread; however, this deception is revealed in tapered balusters having steeper tapers and larger diameter pin tops that show that the feature does not align with the hand rail when aligned with the tread.
Thus, there remains a need for a new and improved stairway system which provides a series of balusters which include features that align both with the tread and the handrail while, at the same time, minimize the number of baluster lengths within an inventory.
The present invention is directed to a stairway system, which includes a plurality of spaced apart treads; a handrail; and at least two balusters per tread. Each baluster includes a top length segment, a bottom length segment and a turning length segment, the turning length segment further includes a portion of defined features. According to the present invention, a length of the turning length segment of a subsequent baluster is greater than a length of the turning length segment of a previous baluster on the same tread according to the equation of the riser height divided by the total number of balusters (for example: 7½″ riser÷2 balusters=3¾″ or 7½″ riser÷3 balusters=2½″). Thus, each of a portion of the defined features in the bottom length segment of each of the balusters align with the tread for each baluster on the same tread.
The stairway system also includes an upright lateral support for supporting the handrail. In the preferred embodiment, the upright lateral support is a newel. One end of the newel is connected to the handrail and the other end of the newel is anchored. Preferably, the newel is connected to the one end of the handrail.
Also, in the preferred embodiment, the newel is vertically anchored, such as to the floor of the structure or to at least one tread. The anchor includes a bolt and a mounting column, wherein one end of the bolt is a wood screw for attaching to the newel. The mounting column preferably further includes a mounting plate attached to the mounting column. The mounting plate may also include a plurality of apertures for receiving fasteners for attaching the plate to the floor of the structure.
The spaced apart treads include a foot support surface and means for attaching the foot support surface to the structure. The width of the foot support surface generally is greater than the depth of the foot support surface. In the preferred embodiment, the means for attaching the spaced apart treads to the structure is a stringer. However, the means for attaching the spaced apart treads to the structure may also be by wall mounting. For example, a stringer supporting the stairs may be attached directly to a wall or with a skirt board between the stringer and the wall.
In the preferred embodiment, each of the spaced apart treads is spaced at a uniform riser height, which may vary between about 6″ and 9″ with about 7½″ being preferred.
Also, in the preferred embodiment, only four different baluster lengths are necessary for both two and three balusters per tread. In this case, the combined length of the top length segment, turning length segment and bottom length segment of each baluster is between 31″ and 46″. Specifically, the first of the four balusters is about 35″, the second baluster is about 39″, the third baluster is between 42″ and 44″, and there is a mid-size baluster between 35″ and 39″. In the most preferred embodiment, the mid-size baluster is about 37½″ and the third baluster of between 42″ and 44″ is about 44″.
Accordingly, one aspect of the present invention is to provide a stairway system, the stairway system including: a plurality of spaced apart treads; a handrail; and at least two balusters per tread, each baluster having a top length segment, a bottom length segment and a turning length segment, the turning length segment including a portion of defined features; wherein a length of the turning length segment of a subsequent baluster is greater than a length of the turning length segment of a previous baluster according to the equation of the riser height divided by the total number of balusters.
Another aspect of the present invention is to provide a stairway system having a plurality of spaced apart treads and a handrail, the improvement including at least two balusters per tread, each baluster having a top length segment, a bottom length segment and a turning length segment, the turning length segment including a portion of defined features; wherein a length of the turning length segment of a subsequent baluster is greater than a length of the turning length segment of a previous baluster according to the equation of the riser height divided by the total number of balusters, wherein each of a portion of the defined features in the bottom length segment of each of the balusters align with the tread for both two balusters and three balusters per tread using only four different baluster lengths.
Still another aspect of the present invention is to provide a stairway system, the stairway system including: a plurality of spaced apart treads; a handrail; at least two balusters per tread, each baluster having a top length segment, a bottom length segment and a turning length segment, the turning length segment including a portion of defined features; wherein a length of the turning length segment of a subsequent baluster is greater than a length of the turning length segment of a previous baluster according to the equation of the riser height divided by the total number of balusters, wherein each of a portion of the defined features in the bottom length segment of each of the balusters align with the tread for both two balusters and three balusters per tread using only four different baluster lengths; and an upright lateral support for supporting the handrail.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.
Referring now to the drawings in general and
As may be seen in
With respect to the at least two balusters 16, it is particularly desirable for portions of features 36 included in the bottom length segment 34 of adjacent balusters communicating with a common tread 12 to define a line segment that aligns with the foot support surface 22 of the tread 12 and portions of features 36 included in the top length segment 30 of adjacent balusters communicating with a common tread 12 as well as balusters communicating with adjacent treads 12 to define a line segment that aligns with the handrail slope. To accomplish this, it is desirable to incrementally change by an integer multiple of the ratio RH/N (where RH is the riser height and N is the number of balusters per tread relative) the length of the turning length segment 32 of the second baluster 28 and, if applicable, any subsequent balusters, relative to the length of the turning length segment 32 of the first baluster 26.
In particular, a reference length of the turning length segment 32 is designated TnLo. In this case, such a length, TnLo, could be designated as being the length of the turning length segment 32 of the first baluster 26. Then the question arises whether the increment for the length of the turning length segment 32 changes when the tread depth, D, is changed.
As a further illustration,
To create systems as depicted in
To each reference length, TnLo, of the turning length segment 32, an increment is added as was previously discussed. To determine the minimum number of baluster lengths needed to accommodate a two balusters per tread stairway system 10 and a three balusters per tread stairway system 10 there is always one reference baluster that is useable in the two baluster per tread stairway system 10 and the three baluster per tread stairway system 10.
Thus, according to the present invention, to be able to maintain an inventory that would allow the manufacture of a two baluster per tread stairway system 10 and a three baluster per tread stairway system 10, the minimum number of baluster lengths is 4. That is, the reference baluster or the first baluster, a second baluster having an increment of 3¾ units for use in the two baluster per tread stairway system 10 and a third baluster having an increment of 2½ units for use in the three baluster per tread stairway system 10 as well as a fourth baluster having an increment of 5 units for the three baluster per tread stairway system 10 thus making a total of four baluster lengths.
In creating an inventory that allows the manufacture of a 4 baluster per tread stairway system 10, 3 baluster per tread stairway system 10 and 2 baluster per tread stairway system 10, the inventory would include 6 unique baluster lengths. To create an inventory that allows the manufacture of a 5 baluster per tread stairway system 10, 4 baluster per tread stairway system 10, 3 baluster per tread stairway system 10 and 2 baluster per tread stairway system 10, the inventory would include 10 unique balusters lengths. To create an inventory that could accommodate 6, 5, 4, 3 or 2 balusters per tread, an inventory of 12 unique baluster lengths would be used. The number of balusters per tread might be extended further to higher numbers and in each case the minimum number of baluster lengths needed to accommodate the patterns to have the alignments of features 36 with the foot support surface 22 of the tread 12 and the handrail slope.
For example as can be learned from the data of
The data of
For the at least two balusters 16 including a first baluster 26 and a second baluster 28 according to the present invention, there are portions of the features 36 that align with the tread 12 to which the at least two balusters 16 communicate and portions of the features 36 that align with the slope of the handrail. This alignment is facilitated by incrementally changing the length of the turning length segment 32 of the second baluster 28 and any subsequent baluster by an increment that is an integer multiple of the ratio RH/N, where RH is the riser height and N is the number of balusters per tread. Adding this integer increment to the reference length, TnLo, of the turning length segment 32 of the first baluster to generate the length of the turning length segment 32 of subsequent balusters accommodates the alignment of portions of the features 36 in the bottom length segment 34 of the balusters with the tread 12 to which the subsequent balusters communicate and portions of the features 36 in the top length segment 30 of the balusters with the slope of the handrail 14.
In creating the stairway system 10 of the present invention, it is advantageous to anchor it to various portions of a structure.
An alternative method of using the anchor 42 is as shown in
A more detailed drawing of the flexible anchor 42 is shown in
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. For example, other methods may be available for anchoring the stairway system 10 of the present invention including, for example, a newel post fastener system having a bolt extending into the newel and a access hole and with a threaded sleeve into which a nut may be inserted (see e.g., part #3072 available from Crown Heritage Stair Systems of North Wilkesboro, N.C., the subject matter of which is incorporated herein in its entirety). It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
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