Baluster Attachment System

The present invention is directed to stairway systems, and more particularly to a system for attaching balusters to a stairway substrate.

Stairway systems are constructed in a variety of different styles and formats depending on their positioning within a building and the desired style and aesthetic. In most cases, however, at least one of the sides of the stairway includes a handrail that is supported by a series of balusters. The balusters provide a functional purpose in preventing an unwanted fall, and also provide an aesthetic purpose in that they can have a variety of shapes and decorative finishes.

Installation of a stairway baluster requires attaching one end of the baluster to a first substrate, which may be a handrail, and the other end of the baluster to a second substrate, which may be a tread, stringer, or other substrate. In some situations, balusters are also installed horizontally, such that the first end is attached to a first newel post and the second end is attached to a second newel post. In any of these situations, the two substrates may be parallel to one another, or may extend at an angle with respect to one another, and the installation may require adjusting one or both ends of the baluster to account for the particular situation and mount the ends flush with both substrates. As builders and installers search for efficient construction methods, there is a continuing need for a system that can enable attachment of balusters to a variety of substrates and in a variety of stairway styles.

The present invention provides a baluster mount system for simply and efficiently attaching balusters to a variety of stairway applications. In one embodiment, the system includes a fastener, a fixed element and a pivot element. The fastener may have a first threaded portion and a second threaded portion, wherein the first threaded portion is threaded into the stairway substrate. The fixed element has a substrate portion and an attachment portion, and the attachment portion includes one of a clevis and a tang extending from the substrate portion. The pivot element has a tubular portion and a secondary attachment portion. The tubular portion includes a sidewall defining an open end, and the secondary attachment portion includes the other of the clevis and the tang. A pin extends through the attachment portion and the secondary attachment portion to pivotally connect the fixed element and the pivot element.

In one embodiment, an end portion of the baluster is inserted into the open end of the tubular portion of the pivot element, and the baluster end may be retained in the tubular portion by a set screw extending through the sidewall of the tubular portion. In another embodiment, the attachment portion is the clevis and the secondary attachment portion is the tang, the tang inserted into the clevis, the pin inserted through the clevis and tang to connect the fixed element to the pivot element.

In one embodiment, the substrate portion of the fixed element abuts the substrate such that it is flush with the substrate. The first threaded end of the fastener may have a first thread pitch, and the second threaded end of the fastener may have a second thread pitch that differs from the first thread pitch. The open end of the tubular portion may have a cross sectional shape that matches the cross sectional shape of the end of the baluster. The pin may define a longitudinal length that forms the axis about which the pivot element can pivot with respect to the fixed element.

The present invention further provides a method for attaching a baluster to a stairway substrate, including the steps of: (a) providing a fastener having a first threaded end and a second threaded end; (b) securing the fastener to the stairway substrate by screwing the first threaded end of the fastener into the substrate with the second threaded end extending out of the substrate; (c) providing a fixed element having a substrate portion at a first end and an attachment portion at a second end opposite the first end; (d) securing the fixed element to the stairway substrate by threading the substrate portion onto the second threaded end of the fastener; (e) providing a pivot element having a secondary attachment portion and a baluster mount; (f) attaching a first end of a stairway baluster to the baluster mount to secure the stairway baluster to the pivot element; (g) positioning the secondary attachment portion of the pivot element adjacent to the attachment portion of the fixed element with the pivot element extending at a desired angle with respect to the fixed element; and (h) inserting a pin through the attachment portion of the fixed element and the secondary attachment portion of the pivot element to connect the pivot element to the fixed element at the desired angle.

A systemfor attaching a balusterto a stairway substrateis shown in the Figs. The systemgenerally includes a fastener, a fixed elementand a pivot element. The pivot elementis connected to the fixed elementwith a pinthat enables attachment of the pivot elementto the fixed elementat a desired angular orientation about an axisbetween the fixed elementand the pivot element, depending on the particular style of stairway.

The fastenermay be one of a variety of fasteners, and in the illustrated embodiment, is in the form of a fastener commonly referred to as a hanger bolt, or in some cases referred to as a lag bolt or screw, having threaded areas at both ends. As shown, the fastenerincludes a first endand a second endopposite the first end. The first endis included in a first threaded sectionextending from the first end, the first endforms a pointin the manner of a lag screw and the first threaded sectionincludes threadshaving a first predetermined thread pitch. The second endis generally flat, in the manner of a bolt, and is included in a second threaded sectionextending from the second end. The second threaded sectionincludes threadshaving a second predetermined thread pitch, which may be different from the first thread pitch.

The fixed elementattaches adjacent to the substrateand provides a fixed base for attachment of the pivot element. In one embodiment, the fixed elementincludes a first endand a second end. As illustrated, the first endfaces the substrateand forms a substrate portion. The second endis opposite the first endand forms an attachment portion. In one embodiment, the substrate portionis generally cylindrical, and includes a threaded openingextending into the first endfor threading onto the second threaded sectionof the fastener. With reference to, the depth of the threaded openingmay be such that the substrate portionis capable of threading onto the fasteneruntil the first endabuts with and is flush against the substrate. The internal threads of the threaded openingmay have a thread pitch that is predetermined to match that of the second threaded sectionof the fastener. The attachment portionmay have various configurations for attaching to the pivot element, and in the illustrated embodiment, the attachment portionincludes a clevishaving a pair of spaced apart flangesdefining a clevis openingbetween them. Each flangedefines a pin holefor receiving the pin. In an alternative embodiment, the fixed elementmay have a cross sectional shape other than the circular cross sectional shape shown in the Figs. to enable the cross sectional shape of the fixed elementto match the shape of the balusteror otherwise provide a desired aesthetic appearance.

The pivot elementpivotally connects to the fixed elementand provides an attachment point for the baluster. In one embodiment, the pivot elementincludes a first endand a second endopposite the first end. The first endforms a secondary attachment portionfor connecting to the fixed element. In one embodiment, the secondary attachment portion is a tangthat is sized and shaped to interfit into the clevis openingbetween the flangesof the clevisof the fixed element, and the tangdefines a pin holethat aligns with the pin holeson the flangesof the cleviswhen the tangis inserted into the clevis. Of course, in an alternative embodiment, the clevisand tangcould be swapped, such that the cleviswas positioned on the pivot elementand the tangpositioned on the fixed element.

The second endof the pivot elementforms a baluster mountfor attaching to a baluster. With reference to, for example, the balustermay include a first end, and the baluster mountis formed as a tubular section of the pivot elementincluding an openingat the second endfor receiving the first endof the baluster. In one embodiment, the tubular section includes a sidewallthat defines a set screw openingfor receiving a set screw. With the first endof the balusterinserted into the baluster mountthrough the opening, the set screwmay be inserted into the set screw openingand tightened to engage the balusterand retain the balusterwithin the baluster mount. In the illustrated embodiment, the balusterhas a generally circular cross section and the tubular section of the baluster mountis provided with a circular cross section to match the shape of the balusterand provide a tight fit for the baluster. Other shapes of the tubular section and the balustermay be used, depending on the desired appearance of the balusterand the pivot element.

In the illustrated embodiment, the pinis provided for connecting the pivot elementto the fixed elementvia the pin holesin the clevisand the pin holein the tang. When the tangis inserted into the clevis opening, the pinis inserted through the aligned pin holes,. The pinmay have opposing ends, and may define a longitudinal length between the opposing ends. The longitudinal length of the pingenerally forms a pivot axisalong which the pinis inserted and about which the pivot elementmay be pivoted or angled with respect to the fixed element. In one embodiment, the fixed elementis positioned such that the longitudinal length of the pinis aligned in a desired direction. For example, as shown in, the pinis aligned perpendicular to the stairway substrateto which it is attached.

Installation of a balusterwith the mounting systemis generally initiated by selecting a desired attachment location on a stairway substrate, and then drilling a hole into the substrateat the desired location and in the desired size for inserting the fastener. The first endis then inserted into the hole by threading the first threaded sectioninto the hole until the entirety, or substantially all, of the first threaded sectionis lodged within the hole. Alternatively, the first endof the fastenercould be directly inserted into the substrate without a pre-drilled hole.

With the first endof the fastenerembedded in the substrate, and the second endprojecting out of the substrate, the fixed elementis attached to the substrateby threading the fixed elementonto the second threaded sectionof the fastener. The fixed elementmay be threaded onto the fasteneruntil the first endabuts the substrateand is flush with the substrate. The fixed elementmay be adjusted as it is attached in order to orient the attachment portionin a desired direction. For example, in the illustrated embodiment where the attachment portionincludes a clevis, the clevismay be oriented in a desired direction to align the pin holessuch that the pinis inserted in a desired direction to provide pivoting of the pivot elementin a desired direction. In one embodiment, the clevismay be positioned such that the pinis inserted perpendicular to the elongated direction of the stairway substrate.

In one embodiment of the invention, the balusteris then connected to the pivot element. More specifically, the balusteris connected to the pivot elementvia the baluster mount. In the illustrated embodiment, this is completed by inserting the first endof the balusterinto the tubular section of the pivot elementthrough the openingat the second endof the pivot element. The first endis inserted beyond the set screw opening, and the set screwis inserted into the opening to engage the balusterand retain the pivot elementon the baluster. In a similar fashion, a second one of the pivot elements, of a second one of the baluster mount systems, may be connected to the second endof the baluster, such that both ends of the balusterare attached to a pivot element. The secondary attachment portionsof each of these pivot elementsmay be aligned with each other so that the pin holesof each pivot elementare aligned and extend in the same direction.

Each pivot elementis connected with an associated fixed element. In one embodiment, this connection is enabled by the insertion of the pin. The pivot elementis positioned such that the tangis inserted into the clevis openingand the pin holeis aligned between the pin holes. The pinis inserted through each of the pin holesin the clevisand the pin holein the tangto connect the pivot elementto the fixed element. In one embodiment, a pivot elementat the second endof the baluster, is similarly attached to an associated fixed elementvia the insertion of an associated pin. Notably, one or more of the pivot elementsmay be oriented at an angle with respect to the associated fixed elementwhen the pinis inserted to make the connection between the pivot elementand the associated fixed element. Conveniently, the pincan be inserted to connect the pivot elementto the fixed elementwith the fixed elementat one of a variety of orientations with respect to the pivot element. For example, in the arrangement of, which is described in more detail below, the baluster mount systemat the first endof the balusteris connected with the fixed elementin vertical alignment with the pivot element, whereas the baluster mount systemat the second endof the balusteris connected with the fixed elementextending at an angle a with respect to the associated pivot element.

Various embodiments of stairway systems are shown in the Figures to illustrate applications of the baluster attachment system. In each arrangement, the systemis used to attach a series of balustersto a stairway substrate, and the particular style and orientation of the substratemay vary from application to application. For example,shows a first style of stairwaythat includes a set of treadsand riserssupported on a cut stringer. In this arrangement, the first endof each of the balustersis attached to one of the treadsusing a first one of the baluster mount systems, and the second endis attached to a handrail. In this arrangement, the fastenerat the first endis embedded into the tread, and the fastener at the second endis embedded into the handrail. The pivot elementand fixed elementat the first endare connected such that they are generally in vertical alignment with each other, while the pivot elementand fixed elementat the second endare angled at about a 45 degree angle with respect to one another as a result of the angle of the handrailwith respect to the vertical balusters.shows a close up view of a single balusterattached to this stairway.

illustrates a second style of stairwaythat includes a set of treadsand risers positioned behind a closed stringer. In this arrangement, the first endof each of the balustersis attached to the closed stringerusing a first one of the baluster mount systems, and the second endof each of the balustersis attached to the handrail. As a result of both the closed stringerand handrailextending at an angle with respect to the vertical balusters, the pivot elementand fixed elementat the first endare angled with respect to one another, and the pivot elementand fixed elementat the second endare also angled with respect to one another. Yet the baluster mount systemmakes both connections easy by attaching the pivot elementsto both ends,, and then connecting each to their respective fixed elementswith respective pins.shows a close up view of a single balusterattached to this stairway.

illustrates a third style of stairwaythat shows the balustersattached between a first newel postand a second newel post. In this arrangement, the fixed elementsare each mounted in a horizontal orientation to a respective one of the posts,. The balustersextend at an angle with respect to horizontal, such that each pivot elementis angled with respect to its associated fixed element. As with all of the illustrated embodiments, the pinsof each baluster mountare aligned with the pinsof all other baluster mountssuch that all pivot elementsare capable of pivoting on an angle in the same direction.shows a close up view of a single balusterattached to this stairway.shows a close up view of a single balusterin an alternative horizontal arrangement, for example where the balusteris mounted between newel posts,of a horizontal railing section. In this arrangement, the pivot elementsat each end of the baluster,are aligned with their associated fixed elements. The ability of the pivot elementsto be connected to their associated fixed elementsat any angle enables the use of this baluster mount systemwith any of the illustrated embodiments, as well as with a variety of stairway embodiments not specifically illustrated in the present application. As noted above, although the fixed elementand pivot elementof the baluster mount systemare illustrated as being cylindrical, other cross sectional shapes may be used in order to match the shape of the baluster, or otherwise provide an ornamental property as desired for the particular application.

An alternative embodiment of the baluster mount system′ is shown in. In this embodiment, the fasteneris replaced with an alternative fastener′, which may be a wood screw′ having a single threaded section′. As shown, the fastener′ includes a first end′ and a second end′ opposite the first end′. The first end′ is included in the threaded section′ extending from the first end′, the first end′ forms a point′ in the manner of a wood screw and the first threaded section′ includes threads′ having a first predetermined thread pitch. The second end′ is a generally conventional screw head.

In this alternative embodiment of the baluster mount system′, the fixed element′ attaches adjacent to the substrate′ and, similar to the first embodiment, provides a fixed base for attachment of the pivot element′. In this embodiment, the fixed element′ includes a first end′ and a second end′. As illustrated, the first end′ faces the substrate′ and forms a substrate portion′. The second end′ is opposite the first end′ and forms an attachment portion′. In this embodiment, the substrate portion′ is generally cylindrical, and as shipped by the manufacturer, includes a closed first end′ (i.e., with no threaded opening). In this embodiment, a threaded opening″ is formed into the fixed element″ by the wood screw′ by inserting the wood screw′ through the second end′ of the fixed element′ and driving the wood screw′ through the substrate portion′ and the first end′ and into the substrate′. With reference to, the wood screw′ is driven through the first end′ and into the substrate′ to a depth such that the substrate portion′ is flush against the substrate′. The attachment portion′ of this embodiment may attach to the pivot element′ in the same manner as described above in connection with the first embodiment.

Installation of a baluster′ with the mounting system′ is generally initiated by selecting a desired attachment location on a stairway substrate′, positioning a fixed element′ at the desired location, and then drilling a hole through the substrate portion′ and through the first end′ and into the substrate′ at the desired location until the wood screw′ is substantially fully inserted and the first end′ is flush with the substrate′.

As in the first embodiment, the fixed element′ may be adjusted as it is attached in order to orient the attachment portion′ in a desired direction, and the baluster′ is then connected to the pivot element′, and a second one of the pivot elements′, of a second one of the baluster mount systems′, is connected to the second end′ of the baluster′, such that both ends of the baluster′ are attached to a pivot element′, and each pivot element′ is connected with an associated fixed elementby the insertion of the pin′.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).

The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.