Slot Rail Assembly

Abstract

The slot rail assembly, in combination with a rail portion, at least one baluster, at least one baluster connector, and a lateral slot and at least one spacer is disclosed and claimed. The baluster may be slid distally along a lateral slot to accommodate the pitch or slope of incline or decline addressed. Lateral movement of the balusters within the lateral slot and change in relative angle of the baluster in relation to the rail portion allows the balusters to stay “plumb” no matter what the pitch of the stairs may be. At least one spacer may be snapped into place to fix the horizontal position of the balusters and to provide a seal against ingress of debris and moisture into the lateral slot. The slot rail assembly may be deployed as a stair rail, a stairway or an improved connection system for balusters and stair rails.

1 . A slot rail assembly comprising:
 a. A rail portion, wherein said rail portion comprises:
 i. A first exterior side wall; 
 ii. A second exterior side wall, wherein said first and said exterior side walls are substantially parallel; 
 iii. A third exterior side wall, wherein said third exterior side wall is non-parallel to either said first or said second side walls, wherein said third side wall is connected to both said first and second side walls; 
 iv. A lateral slot, wherein said lateral slot is positioned within said first said exterior wall, said second exterior wall and said third exterior wall within said rail portion, and wherein said lateral slot comprises:
 1. A first interior side wall; 
 2. A second interior side wall; 
 3. A third interior side wall, wherein said third interior wall connects said first interior side wall to said second interior side wall, wherein said first interior side wall and said second interior side wall are opposed to form an opening; 
 4. A first locking ledge, wherein said first locking ledge is positioned on said first interior wall to protrude into said opening and extends the length of said first interior wall; 
 5. A second locking ledge, wherein said second locking ledge is positioned on said second interior wall to protrude into said opening and extends the length of said second interior wall; 
 
 v. A lateral shelf, wherein said lateral shelf comprises:
 1. A first support shelf located on said first interior wall; 
 2. A second support shelf located on said second interior wall, wherein said first and said second support shelves are positioned interiorly of said first and second locking ledges within said lateral slot; 
 
 vi. Wherein the length of said lateral slot and the length of said rail portion are approximately equal; 
   b. At least one baluster;   c. At least one baluster connector, wherein said at least one baluster is engaged with said least one baluster connector, and wherein said at least one baluster connector comprises:
 i. A skirt portion, said skirt portion positioned partially exterior of said rail assembly; 
 ii. A connecting portion, said connecting portion for attachment to said at least one baluster; 
 iii. A supporting portion, said supporting portion attached to said connecting portion; 
 iv. A pair of projections, said pair of projections positioned between said connecting portion and said support portion, wherein said pair of projections extend away from said connecting portion and said supporting portion; 
   d. At least one spacer, positioned adjacent said at least one baluster, and wherein said at least one spacer is sized and shaped for entry into the side of said lateral slot for positioning between said lateral shelf and said first and said second lockable ledges;   e. Wherein said at least one baluster connector is inserted in said lateral slot for connection with said rail portion, said pair of projections of said at least one baluster connector engaging with said first and said second support shelves of said lateral shelf;   f. Wherein said supporting portion of said least one baluster connector is engaged against said third interior side wall of said lateral slot; and,   g. Wherein the relative angle between said at least one baluster and said rail portion is variable.   
   
   
       2 . The slot rail assembly according to  claim 1  wherein said rail portion is generally u-shaped. 
   
   
       3 . The slot rail assembly according to  claim 1  wherein the length of said at least one spacer may be pre-configured. 
   
   
       4 . The slot rail assembly according to  claim 1  wherein the length of said at least one spacer is selected to determine the angle of the slot rail assembly in relation to the horizontal plane. 
   
   
       5 . The slot rail assembly according to  claim 1  wherein the length of said at least one spacer is selected to plumb the slot rail assembly in relation to the horizon. 
   
   
       6 . The slot rail assembly according to  claim 1  wherein said at least one spacer fixes the location of said at least one baluster connector within said rail portion. 
   
   
       7 . The slot rail assembly according to  claim 1  wherein said at least one baluster connector is both slideable within said lateral shelf and variably angular pivotable with respect to said rail portion. 
   
   
       8 . The slot rail assembly according to  claim 1  wherein said at least one baluster is inserted in said baluster connector. 
   
   
       9 . The slot rail assembly according to  claim 1  wherein said at least one baluster connector is inserted in said baluster. 
   
   
       10 . The slot rail assembly according to  claim 1  wherein the shape of said at least one baluster connector is selected from the group consisting of round, rectangular, triangular, square and combinations thereof. 
   
   
       11 . The slot rail assembly according to  claim 1  wherein the shape of said skirt portion of said at least one baluster connector is selected from the group consisting of round, triangular, rectangular and square and combinations thereof. 
   
   
       12 . The slot rail assembly according to  claim 1  wherein said skirt portion of said at least one baluster, said at least one baluster connector and said at least one baluster are cast and integral. 
   
   
       13 . The slot rail assembly according to  claim 1  wherein the end of said at least one baluster that is not attached to said rail portion is affixed to at least one step. 
   
   
       14 . The slot rail assembly according to  claim 1  wherein both ends of said at least one baluster are engaged with a rail portion. 
   
   
       15 . The slot rail assembly according to  claim 14  wherein both ends of said at least one baluster are engaged with a rail portion. 
   
   
       16 . The slot rail assembly according to  claim 15  wherein said rail portion has a first and a second end, and wherein said first and second ends are connected to at least one end post. 
   
   
       17 . The slot rail assembly according to  claim 16  wherein said first and second ends of said rail portion are connected to at least one hinge, and wherein said at least one hinge is connected to said at least one end post. 
   
   
       18 . A slot rail assembly comprising:
 a. An upper rail, wherein said upper rail comprises:
 i. A first exterior side wall; 
 ii. A second exterior side wall, wherein said first and said exterior side walls are substantially parallel; 
 iii. A third exterior side wall, wherein said third exterior side wall is non-parallel to either said first or said second side wall, wherein said third side wall is connected to both said first and second side walls; 
 iv. A lateral slot, wherein said lateral slot is positioned within said first said exterior wall, said second exterior wall and said third exterior wall within said rail portion, and wherein said lateral slot comprises:
 1. A first interior side wall; 
 2. A second interior side wall; 
 3. A third interior side wall, wherein said third interior wall connects said first interior side wall to said second interior side wall, wherein said first interior side wall and said second interior side wall are opposed to form an opening; 
 4. A first locking ledge, wherein said first locking ledge is positioned on said first interior wall to protrude into said opening and extends the length of said first interior wall; 
 5. A second locking ledge, wherein said second locking ledge is positioned on said second interior wall to protrude into said opening and extends the length of said second interior wall; 
 
 v. A lateral shelf, wherein said lateral shelf further comprises:
 1. A first support shelf located on said first interior wall; 
 2. A second support shelf located on said second interior wall, wherein said first and said second support shelves are positioned interiorly of said first and second locking ledges within said lateral slot; 
 
 vi. Wherein the length of said lateral slot and the length of said first rail portion are approximately equal; 
   b. A lower rail, wherein said lower rail comprises:
 i. A first exterior side wall; 
 ii. A second exterior side wall, wherein said first and said exterior side walls are substantially parallel; 
 iii. A third exterior side wall, wherein said third exterior side wall is non-parallel to either said first or said second side wall, wherein said third side wall is connected to both said first and second side walls; 
 iv. A lateral slot, wherein said lateral slot is positioned within said first said exterior wall, said second exterior wall and said third exterior wall within said rail portion, and wherein said lateral slot comprises:
 1. A first interior side wall; 
 2. A second interior side wall; 
 3. A third interior side wall, wherein said third interior wall connects said first interior side wall to said second interior side wall, wherein said first interior side wall and said second interior side wall are opposed to form an opening; 
 4. A first locking ledge, wherein said first locking ledge is positioned on said first interior wall to protrude into said opening and extends the length of said first interior wall; 
 5. A second locking ledge, wherein said second locking ledge is positioned on said second interior wall to protrude into said opening and extends the length of said second interior wall; 
 
 v. A lateral shelf, wherein said lateral shelf further comprises:
 1. A first support shelf located on said first interior wall; 
 2. A second support shelf located on said second interior wall, wherein said first and said second support shelves are positioned interiorly of said first and second locking ledges within said lateral slot; 
 
 vi. Wherein the length of said lateral slot and the length of said second rail portion are approximately equal; 
   c. A plurality of baluster connectors, wherein each of said plurality of baluster connectors comprises:
 i. A skirt portion, said skirt portion positioned partially exterior of said rail assembly; 
 ii. A connecting portion, said connecting portion for attachment to said at least one baluster; 
 iii. A supporting portion, said supporting portion attached to said connecting portion; 
 iv. A pair of projections, said pair of projections positioned between said connecting portion and said support portion, wherein said pair of projections extend away from said connecting portion and said supporting portion; 
   d. At least one baluster, wherein said at least one baluster has an upper end and a lower end;   e. At least one spacer, positioned adjacent said at least one baluster, and wherein said at least one spacer is sized and shaped for entry into the side of said lateral slot in said upper rail for positioning between said lateral shelf and said first and said second lockable ledges;   f. Wherein said upper end of said at least one baluster is affixed to said baluster connector for insertion in said lateral slot for connection with said upper rail portion, said pair of projections of said at least one baluster end engaging with said first and said second support shelves of said lateral shelf,   g. Wherein said supporting portion of said least one baluster connector is engaged against said third interior side wall of said lateral slot;   h. Wherein the relative angle between said at least one baluster and said rail portion is variable;   i. At least one spacer, positioned adjacent said at least one baluster, and wherein said at least one spacer is sized and shaped for entry into the side of said lateral slot in said lower rail for positioning between said lateral shelf and said first and said second lockable ledges;   j. Wherein said lower end of said at least one baluster is affixed to said baluster connector for insertion in said lateral slot for connection with said lower rail portion, said pair of projections of said at least one baluster connector engaging with said first and said second support shelves of said lateral shelf,   k. Wherein said supporting portion of said least one baluster connector is engaged against said third interior side wall of said lateral slot; and,   l. Wherein the relative angle between said at least one baluster and said rail portion is variable.   
   
   
       19 . The slot rail assembly according to  claim 18  wherein rail portion is generally u-shaped. 
   
   
       20 . The slot rail assembly according to  claim 18  wherein the length of the spacer may be pre-configured. 
   
   
       21 . The slot rail assembly according to  claim 18  wherein the length of the spacer is selected to determine the angle of the slot rail assembly in relation to the horizontal plane. 
   
   
       22 . The slot rail assembly according to  claim 18  wherein the length of the spacer is selected to plumb the slot rail assembly in relation to the horizon. 
   
   
       23 . The slot rail assembly according to  claim 18  wherein said at least one spacer fixes the location of said at least one baluster end within said rail portion. 
   
   
       24 . The slot rail assembly according to  claim 18  wherein said at least one baluster end is both slideable within said lateral shelf and angularly variable pivot with respect to said rail portion. 
   
   
       25 . The slot rail assembly according to  claim 18  further comprising:
 a. The upper rail having a first and a second end;   b. The lower rail having a first and a second end;   c. A first end post, and wherein said first end of said upper rail and said first end of said lower rail are attached to said first end post; and   d. A second end post, and wherein said second end of said upper rail and said second end of said lower rail are attached to said second end post.   
   
   
       26 . The slot rail assembly according to  claim 25  further comprising a plurality of hinges, and wherein said plurality of hinges connect said first end post and said second post to said upper and said lower rails. 
   
   
       27 . The slot rail assembly forming a stairway according to  claim 26  further comprising:
 a. A plurality of steps having a first and second side wherein said first and said second sides are opposing;   b. A set of said upper rails, wherein said set of upper rails are positioned on said first and said second side of said steps; and,   c. A set of said lower rails, wherein said set of lower rails are positioned on said first and said second side of said steps.