SIDE-LOAD VERTICAL RAILING

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/680,970, filed on Aug. 8, 2024, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

Aspects hereof relate to a vertical railing system configured for easier installation.

BACKGROUND

A vertical railing is traditionally used in connection with decking and other surfaces as a barrier. Vertical railing is formed from a plurality of discrete balusters positioned between a top rail and a bottom rail. The assembly of individual vertical balusters between the top tail and the bottom rail is a tedious and labor-intensive task during installation.

BRIEF SUMMARY

Aspects hereof provide for a railing barrier having vertical balusters maintained between a top rail and a bottom rail. The vertical balusters are positioned between the top rail and bottom rail in a side load manner. The bottom rail and a top spacer are positioned between two vertical railing posts. The bottom rail is secured between and to the vertical posts in any suitable manner. The top spacer is also secured between and to the vertical posts in any suitable manner. The individual balusters are positioned along the bottom rail and then tilted into engagement with the spacer. The bottom rail can have any suitable structures to maintain horizontal spacing between the balusters, while also allowing the tilting of the balusters to engage the spacer so as to provide a side loading feature. The spacer also has structure for engaging the balusters as they are tilted into a vertical position from the bottom rail. The spacer can have structure for maintaining horizontal spacing between the individual balusters. The system includes a top rail that is configured to engage the spacer to secure the balusters in their vertical orientation.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is described in detail herein with reference to the attached drawing figures, wherein:

FIG. 1 depicts an example of a side loading railing having balusters installed, in accordance with exemplary aspects hereof;

FIG. 2 depicts an exploded perspective view of a side loading railing, in accordance with aspects hereof;

FIG. 3 depicts an end view with a top rail engaging a top spacer to secure balusters, in accordance with aspects hereof;

FIG. 4 depicts an exploded perspective view of a side loading railing including a baluster in an interim side loading position, in accordance with aspects hereof;

FIG. 5 depicts an exploded perspective view of a side loading railing including an interim position of a plug used for securing a baluster to a bottom rail, in accordance with aspects hereof;

FIG. 6 depicts a perspective view of one spacer for a side loading railing, in accordance with exemplary aspects hereof;

FIG. 7 depicts an exploded perspective view of another side loading railing including another alternative spacer, in accordance with aspects hereof;

FIG. 8 depicts an exploded perspective view of a side loading railing in an interim state of assembly, in accordance with aspects hereof;

FIG. 9 depicts an end view with a top rail engaging a top spacer to secure balusters, in accordance with aspects hereof;

FIG. 10 depicts a perspective view of an alternative spacer for a side load railing, in accordance with aspects hereof;

FIG. 11 depicts an exploded perspective view of a side loading railing including cylindrical balusters, in accordance with aspects hereof;

FIG. 12 depicts an exploded perspective view of a side loading railing including an anti-rattle element for use with round balusters, in accordance with aspects hereof;

FIG. 13 depicts a perspective view of a top rail engaging a top spacer with an anti-rattle element and cylindrical balusters, in accordance with aspects hereof;

FIG. 14 depicts a section view of a plug installed on a bottom rail, in accordance with aspects hereof;

FIG. 15 depicts an exploded perspective view of a stair assembly, in accordance with aspects hereof;

FIG. 16 depicts a side elevation view of a plug for use in a stair assembly, in accordance with aspects hereof;

FIG. 17 depicts an exploded perspective view of another side loading railing including an anti-rattle element, in accordance with aspects hereof;

FIG. 18 depicts an end view of a top rail engaging a round baluster spacer to secure circular balusters, in accordance with aspects hereof;

FIG. 19 depicts an end view of an example round baluster spacer including a retention body and a retention insert, in accordance with aspects hereof;

FIG. 20 depicts an overhead view of an example round baluster spacer, in accordance with aspects hereof;

FIG. 21 depicts a perspective view of an example square baluster spacer, in accordance with aspects hereof;

FIG. 22 depicts an end view of an example square baluster spacer, in accordance with aspects hereof; and

FIG. 23 depicts an end view of a top rail engaging a square baluster spacer to secure square balusters, in accordance with aspects hereof.

DETAILED DESCRIPTION

Aspects hereof provide apparatuses, systems and/or methods directed to a side load vertical railing structure. Specifically, a side load vertical railing is comprised of a top rail, a bottom rail, a spacer, and a plurality of balusters extending between the top rail and the bottom rail. The balusters are loaded into the structure by first positioning each baluster to a securing structure on the bottom rail and then pivoting the baluster into engagement with the spacer extending between adjacent vertical posts. The spacer has structure that holds the balusters in a spaced horizontal relationship. Once all the balusters are in place, the top rail is positioned adjacent the spacer to secure the balusters into the railing framework.

Installation of traditional vertical railing is a labor-intensive process that includes initially mounting a bottom rail between two post members or other structures. The bottom rail typically has holes precut therein to receive the balusters. After the bottom rail is installed, the individual balusters are positioned in the holes on the bottom rail. The top rail is then positioned above the upper ends of the balusters positioned on the bottom rail. The top rail also has precut holes therein that will receive the top ends of the balusters. The top ends of the balusters will have to be aligned with the holes in the top rail as the top rail is put in place between the post members. The balusters during this process are often not maintained in an exact vertical position and may in essence “flop” around in the holes on the bottom rail. This makes positioning the top rail difficult and labor intensive, often requiring two people to do the installation. The above type of installation is referred to as a “stick build” type installation. Another type of traditional installation is a “lay flat” or prebuilt installation where the balusters are positioned between a top and bottom member or rail and secured thereto, before the railing section is positioned between the vertical posts. This is also a labor-intensive process where the entire railing framework needs to be lifted into place and secured to the support posts. This can be particularly unwieldy as the rail sections can be anywhere from 6 to 10 feet long.

Aspects herein contemplate a side load vertical railing comprised of a top rail, a bottom rail, a spacer, and a plurality of balusters extending between the top rail and the bottom rail. The balusters are loaded into the structure by first positioning each baluster to a securing structure on the bottom rail and then pivoting the baluster into engagement with the spacer extending between adjacent vertical posts. The spacer has structure that holds the balusters in a spaced horizontal relationship. Once all the balusters are in place, the top rail is positioned adjacent the spacer to secure the balusters into the railing framework. The provision of the spacer in conjunction with the top rail allows the balusters to be securely held in a vertical, horizontally spaced position during installation. A single individual can install the bottom rail and the spacer between the corresponding vertical posts. The side-load nature of the structure allows the balusters to be individually pivoted into place one at a time and secured in their proper vertical and horizontal position. Once all the balusters are installed, they are permanently held in place by positioning the top rail into engagement with the spacer to effectively secure the balusters and the railing framework.

The aspects contemplated will be discussed in greater detail and with respect to the figures.

Turning to FIG. 1, which depicts an example of a side loading vertical railing system 100 in accordance with aspects hereof. Railing system 100 comprises a top rail 102, a plurality of balusters 104 and 106, and a bottom rail 108. With reference to FIG. 2, the railing system 100 can include a spacer 110 that is used to side mount the balusters 104, 106 and maintain the balusters in their horizontal spacing arrangement. Spacer 110 is attached to and extends between the vertical posts 112 and 114. Spacer 110 can be attached to posts 112 and 114 or any other suitable structure, for instance the brackets 116, as will be more fully described below. The bottom rail 108 also can be connected to the posts 112 and 114 via, for example the brackets 118, as will be more fully described below. With reference to FIGS. 2, 4 and 5, the bottom rail 108 can have a plurality of horizontally spaced holes 120 extending along an upper surface 122 of bottom rail 108. The holes 120 correspond to the laterally spaced locations of the balusters 104, 106. Each of the holes 120 can have a corresponding plug 124 that is snapped into the corresponding hole 120, as will be more fully described below. Each plug 124 has a cylindrical bottom rail engaging pin 126 and generally rectangular protrusion 128 for engaging a corresponding rectangular baluster 104, 106. In contrast, a plug would have a generally cylindrical protrusion for engaging a corresponding rectangular baluster. Each pin 126 can be snapped into the bottom rail during installation. Each plug 124 also has a laterally extending flange 129 that sits on the upper surface 122 of the bottom rail 108.

With reference to FIG. 6, one spacer 110 is described. Spacer 110 includes a top wall 130, a back vertical sidewall 132 and a front vertical sidewall 134. With reference to FIG. 3, the back vertical sidewall 132 is solid and engages a back sidewall 136 of baluster 104, 106 when the baluster is in a vertical assembled position. The back vertical sidewall 132 specifically has an extending flange 138 that engages the back sidewall 136 when the top railing 102 is snapped into place over spacer 110. The top railing 102 has channel 140 that extends longitudinally along its bottom surface 142. In some embodiments, the channel 140 friction fits around the top wall 130, the vertical back sidewall 132 and the front vertical sidewall 134 of the spacer 110 as shown if FIGS. 2 and 3. In some embodiments, the friction fit between the channel 140 of the top rail 102 and the spacer 110 serves to secure the balusters in their final vertical position and to provides a smooth upper hand engaging surface 142 of the top rail 102. The top rail 102 can have any suitable structure (such as an inward extending detent or ridge) that engages the bottom edges 144 and 146 of the spacer 110. The front vertical sidewall 134 has a plurality of horizontally rectangular slots 148 and 150 which allow positioning of the balusters 104, 106 into their vertical positions via a side load action, as will be more fully described below.

With reference to FIGS. 1-5, the side loading assembly of the railing system 100 will be described. First, side posts 112 and 114 are secured in a vertical manner to a horizontal surface, such as a decking surface or other patio surface. Posts 112 and 114 can have an outer decorative sleeve 152 that has a rectangular cross section and that fits around a rectangular inner core 154 made of any suitable material such as wood, metal, or plastic. The inner core 154 can be secured to the deck surface and the sleeve 152 positioned around it. After a sleeve 152 is positioned around the inner core 154, an end cap 156 is positioned on the top edge of the sleeve 152 and inner core 154 to seal each of the posts 112, 114. The end caps 156 can be secure to sleeve 152 and/or inner core 154 in any suitable manner, for instance fasteners or adhesive.

As best shown in FIG. 2, bottom brackets 118 are secured to each of the posts 112 and 114. The bottom brackets 118 can be secured to the post 112 and 114 in any suitable manner, for instance via fastener, such as a screw, or adhesive. The bottom brackets 118 are generally of a block shape and have a generally square/rectangular cross section that engages and matches a square channel 158 formed along the bottom surface of the bottom rail 108 as best shown in FIG. 2. Once the bottom brackets 118 are secured to the posts 112, 114, the top brackets 116 can be secured to the posts 112, 114 in any suitable manner, for instance via fastener, such as a screw, or adhesive. Top brackets 116 can be different from the bottom brackets 118 in the sense that they can have a nose 160 that is of a generally square cross section so as to engage with the top wall 130, back vertical sidewall 132, and front vertical sidewall 134 of the spacer 110. Nose 160 is of a smaller rectangular or square cross section than body 162 of the upper bracket 116. The square cross section of body 162 is generally of the same shape and size as channel 140 of the top rail 102.

After the top bracket 116 and the bottom bracket 118 are secured to their respective posts 112, 114, the top rail 102, bottom rail 108 and spacer 110 can be cut to the appropriate length to span the distance between the posts 112, 114. The bottom rail 108 can then be positioned between the posts 112, 114 such that the bottom rail channel 158 engages with the cross section of the brackets 118. The bottom rail 108 can be secured to brackets 118 in any suitable manner, for instance with a friction fit, or a fastener can be positioned to engage both the bottom rail 108 and the bottom bracket 118. It may also not be necessary to have friction fit or a fastener between the bottom rail 108 and the bottom bracket 118. It may be sufficient to have securement between the top rail 102 and the bracket 116 and spacer 110 to ensure the bottom rail 108 is maintained in position.

With reference to FIGS. 2, 4, 6 and 14, the plugs 124 may be placed in the appropriate holes 120. In particular, with reference to FIG. 14, the bottom cylindrical pin 126 of each plug 124 is positioned in respective hole 120 such that the flange 129 of each plug 124 rests on the upper surface 122 of the bottom rail 108. The plugs 124 are held in place by biasing wedges 164 which are biased inward as the pin 126 of each plug 124 is positioned in its respective hole 120. After biasing wedges 164 pass the lower surface 166 of the bottom rail 108 they snap outwardly to engage the lower surface 166 and secure the plug 124 to the bottom rail 108 to prevent vertical movement. The plugs 124 still can be rotated within holes 120 to allow alignment of the balusters 104, 106. Still further, after the plugs are installed in holes 120, a screwdriver or pliers can be used to depress the biasing wedges 164 inwardly to allow removal of the plug 124. The bottom rail channel 158 allows any sort of tool access to the biasing wedges 164 to allow removal of plugs 124.

The spacer 110 can then be positioned to extend between the post 112 and the post 114 by utilizing the brackets 116. More specifically, the upper bracket nose 160 is configured such that spacer 110 can be snapped into place between the post 112 and the post 114. In some embodiments, spacer 110 is pushed horizontally onto the bracket nose 160 so that the back vertical sidewall 132 and the front vertical sidewall 134 deflect outwardly around the bracket nose 160. In some embodiments, spacer 110 is pushed vertically onto the bracket nose 160. The flange 138 extending inwardly from the back sidewall 132 and the flange 139 extending inwardly from the front sidewall 134 snap around the bottom surface 168 of the nose 160.

Once the spacer 110 is positioned between the posts 112, 114, the balusters 104,106 can then be assembled one at time in a side load fashion. With reference to FIGS. 4 and 5, each baluster 104, 106 can be made with a generally square cross section and can be hollow along its interior. In such a construction, each baluster 104, 106 presents a bottom generally square aperture 170 that can be received over the similarly configured square projection 128 of the plug 124. Each baluster 104, 106 is angled during positioning of the aperture 170 onto the corresponding rectangular projection 128. As the balusters 104, 106 are tilted upwardly, they are received into a corresponding slot 148, 150 of the spacer 110. In this manner, each baluster can be side loaded by first positioning the bottom aperture 170 of each baluster 104, 106 onto the respective projection 128 with the baluster angled. Thereafter, the baluster 104, 106 is tilted upwardly to a vertical position so that the upper end 172 of each baluster 104, 106 is received in its respective slot 148, 150. Each upper end 172 of each baluster 104, 106 rests against the flange 138 of the back sidewall 132 of spacer 110. Once each of the balusters 104, 106 are in place, the bottom channel 140 of the top rail 102 is positioned over the spacer 110 to “lock” the balusters in place. With reference to FIG. 3, channel 140 securely fits around the top wall 130, back sidewall 132 and front sidewall 134 of the spacer 110. Channel 140 can be sized to provide a friction fit around spacer 110 so that the balusters are held in place against the flange 138 and the back sidewall 132. The front surface 174 of the top rail 102 can completely cover slots 148, 150 of the spacer 110. The top rail 102 can be held in place further by a screw or fastener extending through the bracket 116 and into the top rail 102. The screw can pass through either the top surface 142 or the front surface 174 of the top rail 102. In another aspect, the screws are inserted in an upward configuration, such that the spacer 110 and the top rail 102 are coupled together.

Continuing, the top rail 102, the bottom rail 108, and the balusters 104, 106 may be formed from any materials, such as aluminum, steel, any sort of plastic or vinyl. The rails and balusters may have any cross-section shape. For example, in some aspects the rails have a “U” cross-section shape, an “H” cross-section shape, a “T” cross-section shape, and the like. The balusters can also have any cross-section shape such as rectangular, circular, or oval. The rails and balusters may be any length (e.g., 4 ft. to 8 ft.). For example, the rails may come in standard lengths, such as 2 ft., 3 ft., 4 ft., 5 ft., 6 ft., 7 ft., 8 ft., 10 ft., 12 ft., or the like.

With reference to FIGS. 7-10, another spacer configuration is depicted. The structure and operation are the same in this configuration as in the configuration of FIGS. 1-6, other than the configuration of spacer 180. Spacer 180 includes a top wall 182, a back sidewall 184, and a bottom wall 186. The top wall 182 has a downwardly extending flange 188 along its longitudinal length. The bottom wall 186 includes a plurality of slots 190 formed along its length and a plurality of upwardly extending flange segments 192. The bottom rail 108, the brackets 118, and the plugs 124 are all configured and operate in the same manner. Spacer 180 is connected to the top brackets 116 from a side position rather than from a top position. That is to say that the spacer 180 is “snapped” over a portion of the brackets 116 such that the bracket 116 is received through the gap 194 formed adjacent each end of the spacer 180 between the flange 188 and flange segment 192. The spacer 180 is moved laterally such that the brackets 116 pass through the gaps 194 and the flange 188 and flange segments 192 engage the front surface 196 of the bracket 116.

The balusters are side loaded in the same manner as the assembly of FIGS. 1-6. The upper ends 172 of the baluster 104, 106 are received in their respective slots 190 during the tilting action as described above. The flange 188 of the top wall 182 helps to hold the balusters 104, 106 in place. More specifically, flange 188 can engage with the upper end 172 of the baluster 104, 106 as shown in FIG. 9. Additionally, in some embodiments, upwardly extending flange segments 192 can also engage with portions of square baluster 104 and square baluster 106. These engagements help to keep the balusters 104, 106 in place until the top rail 102 can be snapped in place over spacer 180 to lock the balusters 104, 106 in place.

The bottom channel 140 of the top rail 102 is configured to engage the spacer 180 such that the back sidewall 184 and the flange 188 pinch the upper ends 172 of the balusters 104, 106. In some embodiments, the bottom channel 140 engages spacer 180 such that a portion of bottom wall 186 aligned with slots 190 contact the upper ends 172 of the balusters. The upper rail 102 also can be secured to the bracket 116 in any suitable fashion, for instance by a screw or bolt, so as to lock the balusters 104, 106 in place.

With reference to FIGS. 11, 12, and 13 an assembly is depicted to accommodate a baluster 200 with a circular cross section. The assembly uses the spacer 180 of FIGS. 7-10, but could also use the spacer 110 of FIGS. 1-6. The upper ends 202 of the balusters 200 are received in the slots 190 of the spacer 180. The portion of slots 190 proximate the back side wall may be generally square or generally round. However, the portion of slots 190 distal from the back side wall may be open and thus the cross section of the baluster 200 may not engage sufficiently with the back sidewall 184 and flange 188 of the spacer 180. In order to prevent rattle of the circular balusters 200, a buffer strip 204 can be provided during assembly. In some embodiments, the buffer strip 204 can be positioned in the gap 194 of the spacer 180 so that when the top rail 102 is positioned over the spacer 180, the buffer strip 204 puts pressure on the upper end 202 of the baluster 200 to prevent rattling of the circular baluster 200. The buffer strip 204 can be made of any suitable compressible material such as plastic or foam. Alternatively, in at least one embodiment, buffer strip 204 is a rigid insert that engages the balusters and fixes them in place.

With reference to FIG. 15, an assembly is depicted that provides for side loading of the balusters 104, 106 on a stair section 220. Stair section 220 includes a spacer 180 that allows pivoting the balusters 104, 106 into place. In some embodiments, there is a special plug configuration used in conjunction with the bottom rail 108 as shown in FIG. 16. The plug 222 has an angled orientation between the cylindrical pin 126 and the rectangular projection 128. This angled orientation allows for the balusters 104, 106 to be positioned vertically within stair section 220.

Although depicted with spacer 180 engaging with the upper end 172 of the balusters (e.g., baluster 104), other configurations are contemplated. For example, and with reference to FIG. 17, in some aspects a spacer engages with the lower end 176 of the baluster 104 and a bottom rail. As depicted, plug 124 can be used to engage a hole in a top rail 178 that includes a bottom facing wall. Similar to the engagement process of the bottom rail 108, a protrusion of plug 124 engages an aperture 170 at the upper end 172 of baluster 104. Alternatively, a second spacer 180 may be used with upper rail 102 to engage with the upper end 172 of the balusters.

Continuing with reference to FIG. 17, a multi-component bottom rail 179 is depicted in accordance with aspects herein. The multi-component bottom rail 179 may be used as a multi-component bottom rail 179 includes a first piece 179a and a second piece 179b. The first piece 179a and the second piece 179b are configured to cooperatively engage with each other to form the multi-component bottom rail 179. The multi-component bottom rail 179 includes a plurality of notches configured to receive balusters (e.g., baluster 104, baluster 106, or baluster 200). For example, first piece 179a may include the plurality of notches configured to receive balusters. As depicted, the notches may be configured to receive a baluster with a square or rectangular cross section (e.g., baluster 104). Alternatively, the notches may be configured to receive a baluster with a circular or oval cross section (e.g., baluster 200).

With reference to FIGS. 18-20, an example round baluster spacer 1804 is depicted for use with circular balusters (e.g., circular baluster 200) in a railing system. The round baluster spacer 1804 comprises a retention body 1806 and a retention insert 1808, which are configured to cooperatively engage with each other to securely hold circular balusters 200 in place.

FIG. 18 illustrates an end view of the round baluster spacer 1804 in relation to a top rail 102 and a circular baluster 200. The retention body 1806 may have a generally C-shaped cross-section, forming a channel to receive the circular baluster 200. The retention body 1806 includes a side wall 1902, a bottom wall 1904, and a top wall 1910. An angled outer ridge 1906 and an inner ridge 1908 may be formed on the retention body 1806 to provide engagement surfaces for the retention insert 1808.

The retention body 1806 is designed to securely hold the circular baluster 200 while allowing for easy installation and removal. The C-shaped cross-section provides a natural cradle for the baluster, ensuring a snug fit and minimizing potential movement or rattling. The side wall 1902 acts as the primary support structure, while the bottom wall 1904 and top wall 1910 work together to enclose the baluster and distribute the load evenly.

The angled outer ridge 1906 and inner ridge 1908 are crucial features of the retention body 1806. These ridges may serve multiple purposes. For example, the angled outer ridge 1906 and inner ridge 1908 provide a secure attachment point for the retention insert 1808, ensuring that the insert remains firmly in place once installed. The angled design of the outer ridge 1906 allows for easier insertion of the retention insert 1808 during assembly, while also creating a locking mechanism that prevents unintended disengagement. The inner ridge 1908 acts as a stop for the retention insert 1808, ensuring proper positioning and preventing over-insertion. Together, these ridges create a channel that guides the retention insert 1808 into the correct position during installation.

The combination of the C-shaped cross-section and the ridge system allows for a modular design that can accommodate various baluster sizes and styles while maintaining structural integrity and ease of installation. This design also facilitates potential future upgrades or replacements of individual components without necessitating a complete overhaul of the railing system.

FIG. 19 shows a cross-sectional view 1900 of the round baluster spacer 1804, providing a detailed illustration of the structural relationship and mechanical interaction between the retention body 1806 and the retention insert 1808. The retention body 1806 forms the primary structural component of the spacer with its C-shaped profile, while the retention insert 1808 serves as a complementary component that secures the circular baluster in position. The retention insert 1808 includes a bottom flange 1912 that extends horizontally along the inner surface of the bottom wall 1904 of the retention body 1806, creating a stable base that distributes force evenly across the connection point. In some embodiments, a portion of bottom flange 1912 engages the upper portion of a baluster (e.g., circular baluster 200). Advantageously, the combination of retention body 1806 and retention insert 1808 engaging with a baluster can conceal the inner cavity of the spacer and restrict the penetration of debris and insects into said cavity. A side flange 1914 extends vertically upward from the bottom flange 1912 at approximately a right angle, following the interior contour of the retention body 1806 and providing lateral stability to the assembly. This side flange 1914 terminates in a specialized clip portion 1916 that has been engineered with specific dimensions and geometry to create a secure mechanical connection. The clip portion 1916 is precisely configured to engage in the space between the inner ridge 1908 and the angled outer ridge 1906 of the retention body 1806, creating a snap-fit connection that securely locks the retention insert 1808 in place while still allowing for intentional disassembly when needed. This interlocking arrangement ensures that the retention insert 1808 remains firmly positioned during normal use of the railing system while accommodating the stresses and forces typically encountered in such applications.

FIG. 20 depicts an overhead view 2000 of the round baluster spacer 1804, illustrating how the components fit together to form a complete assembly. The retention body 1806 may include a baluster slot 2004 configured to receive the circular baluster 200. The retention insert 1808 may be positioned within a retention slot 2002 of the retention body 1806. When assembled, the retention body 1806 and retention insert 1808 cooperate to form a secure mounting system for the circular baluster 200.

In some aspects, the round baluster spacer 1804 may be configured to interface with the top rail 102, providing a transition between the circular baluster 200 and the top rail 102. The retention body 1806 and retention insert 1808 may be made of materials that allow for some flexibility during assembly while maintaining structural integrity when in use, such as high-density polyethylene (HDPE), polypropylene, nylon, or certain grades of polyvinyl chloride (PVC). These polymer materials provide the ideal balance of flexibility for snap-fit assembly operations while offering sufficient rigidity and durability for long-term structural performance in outdoor environments. Thermoplastic elastomers (TPEs) may also be suitable for applications requiring additional vibration dampening properties, while reinforced composites containing glass or carbon fibers can provide enhanced structural strength without sacrificing the necessary flexibility during installation. The design of the round baluster spacer 1804 may allow for easy installation of circular balusters 200 while ensuring a secure fit within the railing system.

With reference to FIG. 21, FIG. 22, and FIG. 23, a square baluster spacer 2102 may be provided for use in a railing system. The square baluster spacer 2102 may comprise a top wall 2108, a side wall 2110, and a bottom wall 2112. In some cases, the top wall 2108, side wall 2110, and bottom wall 2112 may form a channel configured to engage with a corresponding channel in a top rail 2116 of the railing system.

The square baluster spacer 2102 may include a back vertical sidewall extending downward from the top wall 2108. A front vertical sidewall may extend downward from the top wall 2108 and be spaced apart from the back vertical sidewall. In some implementations, the square baluster spacer 2102 may comprise a plurality of horizontally spaced rectangular notches formed in the front vertical sidewall.

The bottom wall 2112 of the square baluster spacer 2102 may include a plurality of slots. These slots may be positioned along the bottom wall 2112 and may be configured to receive upper ends of balusters when the balusters are tilted into a vertical position. The rectangular notches in the bottom wall 2112 may be sized to allow positioning of square balusters into their vertical positions via a side load action.

A baluster slot 2104 may be formed in the square baluster spacer 2102. The baluster slot 2104 may be configured to accommodate a square baluster 2114. In some cases, the square baluster spacer 2102 may further comprise a front flange (e.g., retention flange 2106) extending downwardly from the top wall 2108.

The square baluster spacer 2102 may include a retention flange 2106. The retention flange 2106 may extend downwardly from the top wall 2108 at various angles to accommodate different installation requirements. For example, the retention flange 2106 may extend at a 90-degree angle for maximum engagement with square balusters, at a 75-degree angle to provide some flexibility during installation while maintaining secure retention, or at a 60-degree angle to facilitate easier side-loading of balusters while still providing sufficient retention force. In some implementations, the retention flange 2106 may be configured to engage a back surface of the square baluster 2114 when the square baluster 2114 is in a vertical assembled position. The retention flange 2106 may be constructed from various materials to optimize performance characteristics, including rigid materials such as nylon, polyvinyl chloride (PVC) , high-density polyethylene (HDPE), or aluminum for maximum strength and durability. Alternatively, the retention flange 2106 may be formed from semi-flexible materials such as thermoplastic elastomers (TPEs) or polypropylene to provide some compliance during installation while maintaining sufficient rigidity to secure the balusters in their final position. In outdoor applications, the retention flange 2106 may be constructed from UV-resistant polymers or powder-coated metals to ensure long-term performance despite exposure to environmental elements.

The channel formed by the square baluster spacer 2102 may be configured to provide a friction fit with the corresponding channel of the top rail 2116. This friction fit may help secure the square baluster spacer 2102 in place within the railing system.

In some cases, the square baluster spacer 2102 may be constructed from flexible materials such as thermoplastic elastomers (TPEs), polyethylene, polypropylene, or flexible PVC compounds that provide sufficient resilience during installation while maintaining structural integrity when in use. These materials offer the advantage of allowing slight deformation during the side-loading process, then returning to their original shape to securely hold the balusters in place. Silicone-based polymers and certain rubber compounds may also be suitable for applications requiring enhanced vibration damping properties. In some embodiment, square baluster space 2102 may be constructed from metal. The dimensions of the square baluster spacer 2102 may vary based on the specific requirements of the railing system in which it is used.

The square baluster spacer 2102 may contribute to the overall assembly of the railing system by providing a secure interface between the top rail 2116 and the square baluster 2114. The retention flange 2106 and the baluster slot 2104 may work together to maintain the square baluster 2114 in its proper vertical orientation within the railing system.

From the foregoing, it will be seen that this disclosure is one well-adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious, and which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

While specific elements and steps are discussed in connection to one another, it is understood that any element and/or steps provided herein is contemplated as being combinable with any other elements and/or steps regardless of explicit provision of the same while still being within the scope provided herein. Since many possible embodiments may be made of the disclosure without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.

As used herein and in connection with the claims listed hereinafter, the terminology “any of clauses” or similar variations of said terminology is intended to be interpreted such that features of claims/clauses may be combined in any combination. For example, an exemplary clause 4 may indicate the method/apparatus of any of clauses 1 through 3, which is intended to be interpreted such that features of clause 1 and clause 4 may be combined, elements of clause 2 and clause 4 may be combined, elements of clause 3 and 4 may be combined, elements of clauses 1, 2, and 4 may be combined, elements of clauses 2, 3, and 4 may be combined, elements of clauses 1, 2, 3, and 4 may be combined, and/or other variations. Further, the terminology “any of clauses” or similar variations of said terminology is intended to include “any one of clauses” or other variations of such terminology, as indicated by some of the examples provided above.

The following clauses are aspects contemplated herein.

Clause 1. A railing system comprising: a top rail; a spacer positioned adjacent the top rail; a bottom rail; a plurality of balusters extending between the top rail and the bottom rail; wherein the bottom rail has a plurality of securing structures for horizontally securing a bottom portion of each baluster while allowing tilting of the baluster to a vertical position; and wherein the spacer has a plurality of slots that receive the upper ends of the balusters when they are tilted into a vertical position during assembly.

Clause 2. The railing system of clause 1, further comprising a plurality of plugs positioned along the bottom rail and engaging a bottom portion of the balusters to allow the balusters to be tilted into a vertical position.

Clause 3. The railing system of clause 2, wherein the bottom rail has a plurality of holes for engaging a first portion of the plugs.

Clause 4. The railing system of clause 3, wherein each plug has a second portion for engaging a lower end of the baluster.

Clause 5. The railing system of clause 1, wherein the top rail has a channel that engages the spacer along its length to hold the balusters in place.

Clause 6. The railing system of clause 1, wherein the slots in the spacer are positioned along a front vertical sidewall of the spacer.

Clause 7. The railing system of clause 1, wherein the balusters are of a circular cross section, and the railing system further comprises a buffer strip extending along the spacer to prevent rattling of the circular balusters.

Clause 8. The rail system of any of clauses 1-5, wherein the slots in the spacer are positioned along a bottom wall of the spacer.

Clause 9. The rail system of any of clauses 1-8, wherein the balusters are of a square cross section.

Clause 10. The rail system of any of clauses 1-9, wherein the balusters are of a circular cross section.

Clause 11. The rail system of clause 10, further comprising a buffer strip extending along the spacer to prevent rattling of the circular balusters.

Clause 12. The railing system of clause 11, wherein the buffer strip is a rigid and fixedly engages the circular balusters.

Clause 13. A round baluster spacer for use in a railing system, comprising: a retention body having a generally C-shaped cross-section forming a channel to receive a circular baluster, the retention body including a side wall, a bottom wall, and a top wall; an angled outer ridge and an inner ridge formed on the retention body; and a retention insert configured to cooperatively engage with the retention body, the retention insert including a bottom flange extending along an inner surface of the bottom wall of the retention body, a side flange extending upward from the bottom flange, and a clip portion configured to engage between the inner ridge and the angled outer ridge of the retention body.

Clause 14. The round baluster spacer of clause 13, wherein the retention body further comprises a baluster slot configured to receive the circular baluster.

Clause 15. The round baluster spacer of clause 14, wherein the retention body further comprises a retention slot configured to receive the retention insert.

Clause 16. The round baluster spacer of clause 15, wherein the clip portion of the retention insert is configured to snap-fit between the inner ridge and the angled outer ridge of the retention body.

Clause 17. The round baluster spacer of clause 16, wherein the retention body and the retention insert are made of materials that allow for flexibility during assembly while maintaining structural integrity when in use.

Clause 18. The round baluster spacer of clause 17, wherein the retention body is configured to interface with a top rail of the railing system, providing a transition between the circular baluster and the top rail.

Clause 19. The round baluster spacer of clause 18, wherein the retention body and retention insert cooperatively form a secure mounting system for the circular baluster that allows for easy installation while ensuring a secure fit within the railing system.

Clause 20. A square baluster spacer for use in a railing system, comprising: a top wall; a vertical sidewall extending downward from the top wall; a bottom wall extending horizontally from the sidewall and spaced apart from the top wall; a plurality of horizontally spaced rectangular notches formed in the bottom wall; and a downwardly extending flange on the top wall configured to engage a surface of a square baluster when the square baluster is in a vertical assembled position.

Clause 21. The square baluster spacer of clause 20, further comprising an upwardly extending flange from the bottom wall.

Clause 22. The square baluster spacer of clause 21, wherein the top wall, vertical sidewall, and bottom wall form a channel configured to engage with a corresponding channel in a top rail of the railing system.

Clause 23. The square baluster spacer of clause 22, wherein the channel formed by the square baluster spacer is configured to provide a friction fit with the corresponding channel of the top rail.

Clause 24. The square baluster spacer of clause 23, wherein the rectangular notches in the bottom wall are sized to allow positioning of the square balusters into their vertical positions via a side load action.

Clause 25. The square baluster spacer of clause 24, wherein the downwardly extending flange on the top wall is configured to engage with the back surface of the square baluster when a top rail is snapped into place over the square baluster spacer.

Clause 26. A method of assembling a railing system including a bottom rail, a top rail, a spacer and a plurality of balusters, the method comprising: positioning a baluster on the bottom rail in a non-vertical orientation; tilting the balusters to a vertical orientation such that they engage the spacer; and positioning the top rail onto the spacer to secure the balusters.

Clause 27. The railing system of clause 26, further comprising positioning plugs along the bottom rail to secure the lower ends of the balusters.

Clause 28. The railing system of clause 27, further comprising positioning laterally spaced slots on the spacer to receive the upper ends of the balusters.