US-20260125910-A1 - RAILING ASSEMBLY HAVING BALUSTERS WITH LOCKING TABS

US20260125910A1US 20260125910 A1US20260125910 A1US 20260125910A1US-20260125910-A1

Abstract

A quick install baluster is provided for efficiently and installing balusters onto a rail. A railing is formed using a baluster having a tab in sidewall of the baluster proximate an end of the baluster. The tab may be flared outwards such that the end of the baluster including the tab may be inserted into an opening of a rail but the tab prevents removal of the tab and baluster through the opening of the rail.

Inventors

Chris Ferron

Assignees

Envision Outdoor Living Products LLC

Dates

Publication Date: 20260507
Application Date: 20251106

Claims (20)

1 . A railing comprising: a baluster including a tab in a sidewall of the baluster, the tab having a first end connected to the sidewall and a second end disconnected from the sidewall, the first end of the tab being closer to an end of the baluster than the second end of the tab; and a rail having a first wall including an opening defined therethrough, the opening having a shape and size approximately corresponding to a cross-section of the baluster; wherein the second end of the tab flares outward relative to the sidewall such that the tab of the baluster may be inserted through the opening of the rail in a first direction and such that the tab prevents the tab and the baluster from passing through the opening of the rail in a second direction opposite the first direction.
2 . The railing of claim 1 , wherein the baluster is made of a vinyl material.
3 . The railing of claim 1 , wherein the tab is one of a pair of tabs in opposing sidewalls of the baluster.
4 . The railing of claim 3 , wherein the second end of each of the pair of tabs flares outward relative to the sidewall such that a first width between the second ends of the pair of tabs is greater than a second width of the opening of the first wall of the rail.
5 . The railing of claim 1 , wherein the first direction is a direction from the second end of the tab to the first end of the tab.
6 . The railing of claim 1 , wherein the baluster includes the tab at one end of the baluster and includes a second tab at another end of the baluster.
7 . The railing of claim 1 , wherein first and second side portions of the tab between the first end and the second end are severed from the sidewall such that the tab is connected to the sidewall only by the first end.
8 . The railing of claim 1 , wherein the rail includes a second wall opposite the first wall, the second wall spaced from the first wall a first distance, wherein the second end of the tab is spaced a second distance from the end of the baluster, wherein the second distance is less than the first distance.
9 . A railing assembly comprising: a post; a bracket mounted on the post; a rail coupled to the bracket to be at least partially supported by the bracket, the rail having a first wall including an opening therethrough; and a baluster including a pair of tabs in opposing sidewalls of the baluster, each of the pair of tabs having a first end connected to the sidewall and a second end that is disconnected from the sidewall, the first end of the tab being closer to a distal end of the baluster than the second end of the tab; wherein the baluster extends through the opening of the first wall of the rail such that the pair of tabs are positioned inside the rail; wherein the second end of each of the pair of tabs flares outward relative to the sidewall such that a first width between the second ends of the pair of tabs is greater than a second width of the opening of the first wall of the rail.
10 . The railing assembly of claim 9 , wherein the second ends of the pair of tabs abuts the first wall of the rail to prevent removal of the baluster through the opening of the rail.
11 . The railing assembly of claim 9 wherein the baluster is made of a vinyl material.
12 . The railing assembly of claim 9 , wherein the baluster includes the pair of tabs at one end of the baluster and includes a second pair of tabs at another end of the baluster.
13 . The railing assembly of claim 9 , wherein first and second side portions of each tab between the first end and the second end are severed from the sidewall such that each tab is connected to the sidewall only by the first end.
14 . A baluster for a railing assembly, the baluster comprising: a sidewall; and a tab formed in the sidewall proximate an end of the baluster, the tab having a first end connected to the sidewall and a second end disconnected from the sidewall, the first end of the tab being positioned between the end of the baluster and the second end of the tab; wherein the second end of the tab flares outward relative to the sidewall to provide a locking mechanism when the baluster is inserted through an opening in a rail.
15 . The baluster of claim 14 , wherein the tab is formed by punching out a portion of the sidewall of the baluster such that the second end and first and second side portions of the tab between the first end and the second end are severed from the sidewall.
16 . The baluster of claim 14 , wherein the baluster includes a second tab formed in the sidewall proximate another end of the baluster.
17 . The baluster of claim 14 , wherein the tab is one of a pair of tabs in opposing sidewalls of the baluster.
18 . The baluster of claim 17 , wherein the second end of each of the pair of tabs flares outward relative to its respective sidewall such that a first width between the second ends of the pair of tabs is greater than a second width of the opening in the rail.
19 . The baluster of claim 14 , wherein the tab is configured to deflect inwardly when forced through the opening and is configured to return to its outwardly flared position once positioned inside the rail.
20 . The baluster of claim 14 , wherein the sidewall has a first width and the tab has a second width that is approximately 40-75% of the first width.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This Application claims priority to U.S. Provisional Patent Application Ser. No. 63/717,236, filed on Nov. 6, 2024, to Chris Ferron, entitled “Railing Assembly Having Balusters with Locking Tabs,” currently pending, the entire disclosure of which is incorporated herein by reference. BACKGROUND Railing assemblies may include balusters extending between and coupled to rails. Conventional railing assemblies couple the balusters to the rails using methods that often permit the baluster to separate from or pop out of the rail until the railing assembly is fully assembled locking the rails in a fixed position. Thus, forming the railing by coupling the balusters to the rails can often require significant rework. Other methods for installing balusters to rails can require significant time, tools, or experience and can require multiple installers. Additionally, conventional railings can be difficult to move as a unit meaning the balusters must often be installed on the rails in the final install position. This reduces workflow flexibility and increases installation time. Accordingly, a need exists for a baluster that can be efficiently, easily, and securely installed to the rails. Additionally, a need exists to be able to preassemble the baluster and rails to create a railing section that can then be easily moved to the final install position to increase installation efficiency and promote workflow flexibility, thereby saving on overall labor and installation costs. SUMMARY The present invention is directed generally to a baluster for efficient, easy, and secure installation to a rail to form a railing for a railing assembly. The baluster may include a locking tab proximate an end of the baluster that is inserted through an opening in the rail. The tabs may be flared outwards relative to a surface of the baluster, and the tabs may be made of a stiff material, such as vinyl. The baluster and tab may be forced through or pushed through the opening. The tab may deflect to pass through the opening and then snap back to its flared position to lock the end of the baluster within the rail. The tab may prevent the baluster from being removed through the opening in the opposite direction from which it was inserted. Thus, balusters may be easily inserted into the rail and locked into a position where the baluster will not pop back out of the rail to form an assembled section of railing. This work can be done in a staging area and the section of railing can be carried or transported to the final install location without the assembled section of railing coming apart. In one independent aspect, a railing includes a baluster having a tab in a sidewall of the baluster, the tab having a first end connected to the sidewall and a second end that is disconnected from the sidewall, the first end of the tab being closer to an end of the baluster than the second end of the tab; and a rail having a first wall including an opening therethrough, the opening having a shape and size approximately corresponding to a cross-section of the baluster. The second end of the tab flares outward relative to the sidewall such that tab of the baluster may be inserted through the opening of the rail in a first direction and such that the tab prevents the tab and baluster from passing through the opening of the rail in a second direction opposite the first direction. Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views: FIG. 1 is a side elevation view of a railing assembly in accordance with one embodiment of the present invention; FIG. 2 is an exploded perspective view of a portion of the rails and baluster of the railing assembly of FIG. 1; FIG. 3 is a side view of a portion of the baluster of FIG. 2; FIG. 4 is a section view of the portion of the baluster of FIG. 3, viewed along section 4-4; FIG. 5 is an upper view of the baluster of FIG. 2; FIG. 6 is a side view of the rails and baluster of FIG. 2 shown in an assembled position; FIG. 7 is an enlarged view of a portion of the rail and baluster of FIG. 6; FIG. 8 is a section view of the rail and baluster of FIG. 7, viewed along section 8-8; and FIG. 9 is an enlarged view of a portion of the rail and baluster of FIG. 6 shown with the baluster in a different orientation. DETAILED DESCRIPTION The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing