Patent Application
20130283711
The present invention relates to a staircase. More specifically, the present invention relates to a precision built staircase.
It is therefore an object of this invention to provide a precision built staircase that is relatively quicker and easier to assemble, has a relatively more (longer lasting) aesthetically pleasing appearance and utilizes relatively more precise pre-manufactured profiled structural stringers and pre-profiled decorative stringers than current staircases.
It is another object of the invention to provide a precision built staircase with an added standard or universal skirt board and a plurality of accessories that can be assembled in a few minutes that are in compliance with various building codes and standards.
It is also an object of the invention to provide a precision built staircase with a plurality of components with a plurality of aesthetic embodiments that can be manufactured on precision machinery such as a CNC router machine. (preferably face to face for a raw material economy from 26 to 38% for the first set of structural stringers and eliminate the need to make and other set when come the time to install the decorative final staircase (another 100%)
It is an object of the invention to provide a precision built staircase that ensures consistent dimensional productivity and installation at the right position with a plurality of winder's treads and risers set by utilizing a starter winder tread plank and a pre-profiled nose angled to a plurality of winder's treads that are also relatively easy to fix, well-aligned at the front surfacing and angled at 90 degrees to the front of the starter winder tread plank and are relatively quickly installable into a starter winder tread plank slot for a relatively better final result.
It is another object of the invention to provide a precision built staircase that allows relatively easy and rapid assembling and attachment of the staircase components that includes a plurality of pre-drilled apertures and a plurality of standard and Universal brackets that can be glued together without any excess overflow of glue to a plurality of treads, risers and stringers.
It is also another object of the invention to provide a plurality of standard and Universal skirt board that can be temporarily or permanently used at a plurality of predetermined heights that are attached securely with one or more covers and one or more corner joints.
It is an object of the invention to provide a precision built staircase with a plurality of components that could be easily sold and kept in stock across all distributors, retailers, agents, installers, finishers and do-it-yourself suppliers on the market.
It is another object of the invention to provide a plurality of precision built staircase components that can be easily stocked in a weather regulated warehouse or store, that includes structural stringers, decorative stringers, universal skirt boards and other stair components that will not warp, curve, crack or split by using kiln dried, engineered composite materials and/or others.
It is another object of the invention to provide a precision built staircase in a kit form in a pre-assembled box that can be used as a cabinet, a closet or an outside shell that is also available in a pre-finished or a non-finished form.
It is another object of the invention to provide a precision built staircase that can utilize a plurality of different sizes, types, lengths, gages, with or without headed nails and screws.
It is another object of the invention to provide a precision built staircase that is made of composite, hard, softwood, aluminum, steel, concrete, marble, granite, rough or prefinished materials, or other suitable engineered materials pre-assembled or non-pre-assembled.
It is another object of the invention to provide a precision built staircase that can utilize a wide variety of glue types.
It is another object of the invention to provide a precision built staircase and related components that can be manufactured in any desired shape, size, and/or dimension.
The present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawing in which like references denote similar elements, and in which:
Various aspects of the illustrative embodiments will be described using terms commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. However, it will be apparent to those skilled in the art that the present invention may be practiced with only some of the described aspects. For purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the illustrative embodiments. However, it will be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well-known features are omitted or simplified in order not to obscure the illustrative embodiments.
Various operations will be described as multiple discrete operations, in turn, in a manner that is most helpful in understanding the present invention. However, the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations need not be performed in the order of presentation.
The phrase “in one embodiment” is used repeatedly. The phrase generally does not refer to the same embodiment, however, it may. The terms “comprising”, “having” and “including” are synonymous, unless the context dictates otherwise.
In accordance with these objects which will be discussed in detail below, the present invention provides a complete line of modified stair components and, when assembled together with a plurality of accessories and a stair kit reduce installation time, achieve a relatively higher percentage savings of raw material, manufacturing time, and installation time with a relatively high precision.
The invention relates to a staircase 500, more particularly, the invention relates to modifications and ameliorations brought to a plurality of typical staircase components utilized that make the staircases relatively easier to install and are typically more economical to manufacture saving manufacturing time, raw material and 30 to 70% of the installation time due to the relatively high precision of preferred machinery (e.g. CNC router) used to produce many of the staircase components 500. When all of the components will be assembled, the final result will be a relatively better temporary or permanent fit. It will permit the re-use of the structural stringer 3 installed at the beginning of construction permanently and only replace a rough tread 18 and a riser 17 initially temporary installed by a plurality of chosen decorative treads 1-10 and risers 200, a decorative stringer 4, a pre-profiled skirt board 5 and any other desired components, pre-finished or to be finished.
Staircases currently available on the market are mostly assembled on a job site and to save installation time, few distributors offer them pre-assembled which can also be prefinished. When assembled on a job site, most of the time, stringers 3 are cut manually with a skill saw typically 2″×2″×12″ which is where precision discrepancies occur. When the staircases are assembled at a manufacturing site, they do not necessary have the high precision machines (CNC router) to perfectly cut the stringers 3, 4 and other high precision components cut. Typically it's very difficult to determine in advance the precision squaring and leveling the walls, floors and ceiling formed 95% of the time in a new building or a remodeled job site, resulting that some percentage of components fabricated or adjusted on site must be reprocessed, resulting in a relatively costly operation.
Installation of staircase 500 is considered by professional building contractors to be relatively complicated work. It is imperative to introduce into a relatively large market, products that can be installed in less time and with more efficiency and precision. Structural stringers 3 are a significant part of substantial saving in manufacturing, raw material, installation time and an attractive final long lasting aesthetic appearance. Regarding the stringers 3, 4 and pre-profiled skirt board 5; the manufacturing's precision and relative rapid execution offer distributors, retailers and others a reasonable price and better compliance of building codes. Structural stringers, 3, decorative stringers 4, a pre-profiled skirt board 5 and a plurality of winder's treads 201,202,203 can be manufactured in a through panel, that can also be reversible, made of many materials such as engineered, laminated, plywood, composite, kiln dried or other suitable materials to reduce the components curving, warping, cracking, shrinking or expanding too much. All these elements are required to be avoided so that precise manufacturing at the beginning of the manufacturing process may avoid the need to reinstall new stringers 3, 4 when it's time to install the final permanent decorative staircase.
The height of risers 47A and tread's runs 46 staying precise allows further ameliorations to these components for an easier and quicker installation.
The pair of skirt boards includes a plurality of stringer types 501,601,701, 801, 901, 1001, risers 200 treads 1, 10, 18, dowels 205, springs 206, aperture 210, slot 208, profiles and grooves 701A, 801A.
Universal square 15 firmly maintains the desired position in regards to temporarily or permanently attached treads 1-10, risers 200 and stringer 3. Two pieces of sticky and spongy material 15A are added on top of universal square 15 to be attached to treads 1-10 underneath and at least one piece of sticky and spongy material 15A such as cork, foam, rubber, or felt are added at the vertical front side of the universal square 15 to be attached at the rear risers 200B. The piece of sticky and spongy material 15A is typically square or round and is auto-adhesive which will act as a spacer being squeezed when screwed through the bracket aperture from the back to the tread 1-10 and riser 200, resulting in a relative tighter fit to the stringer 3.
Cover joint 18a, 18b, 18c and corner joints 2540 will time efficiently cover a plurality of cuts 18B at joint eliminating touch-up areas.
Starter winder tread plank 101 assures the installation of winder's treads 1,2,3 to firmly and accurately align each other in a plurality of predetermined single recessed slots 1A,2A,3A at a predetermined precise riser height desired and to tightly attach winder's risers 1B,2B,3B at right angles to the adjacent wall 550, starter winder tread plank 101, winder's treads 1,2,3 together.
Starter winder tread plank 101 assures the installation of winder's treads 1,2,3 to firmly and accurately align each other in a plurality of predetermined double recessed slots 1A,2A,3A and to tightly attach winder's risers 1B,2B,3B at right angles to the adjacent wall 550, starter winder tread plank 101, winder's treads 1,2,3 together.
Pre-profiled skirt board 5 will be installed relatively quickly without any scratches on treads or risers such as pre-finished treads or risers using a plastic tape 6, with a resistant pre-glued 7 at one side of the plastic tape 6. The pre-profiled skirt board 5 is laid down over plastic tape 6 preinstalled at a wall side over treads 10 and risers 1 then the universal skirt board 2631 is slid-up to the front of risers 1 and is pushed to the wall 550. One or more nails 16 or screws 19 that secure the pre-profiled skirt board 5 to wall 550 are hid with an overlap angled molding 560. The plastic tape 6 can be removed by manually tearing-off the plastic tape 6. The plastic tape 6 can similarly be utilized for pre-profiled skirt board of a winder's set.
One or more tread's end cap 11, 12, 13 shown in
Bottom rear tread radius when tread are nosed right and or left side (to be discussed
Pre-profiled 5 and universal skirt board 2631 adds a desired aesthetic fit and hide nails 16 and/or screws 19 used at top side of treads 10 and risers 1,17,200 and/or space between the wall 550 and treads and risers, when there is, in straight 500 or winder's installation
Decorative starter plank jacket 100 can be added any time after treads and risers are installed over the rough starter plank 99 and holder of starter plank. To build a straight staircase 500 on-site will save from 4 to 6 hours of installation time in contrast to a traditional staircase and to built on site a L-shaped staircase 500 with a set of 3 winder's treads and risers, the saving time will be up to 6 to 9 hours in contrast to a traditional staircase. This relatively large time savings will be appreciated by professional building contractors and do-it-yourself customers who wish to install their own staircase.
Decorative starter plank jacket 100 can be added any time after treads and risers are installed over the rough starter plank 99 and holder of starter plank. To build a straight staircase 500 on-site will save from 4 to 6 hours of installation time in contrast to a traditional staircase and to built on site a L-shaped staircase 500 with a set of 3 winder's treads and risers, the saving time will be up to 6 to 9 hours in contrast to a traditional staircase. This relatively large time savings will be appreciated by professional building contractors and do-it-yourself customers who wish to install their own staircase.
Prior to installing a plurality of rough risers 17 of treads 18, structural stringers 3 are installed at a precise position initially with glue and are then nailed or screwed to wall 550.
Top 207 and bottom of risers are nailed or screwed to riser height 570 of structural stringer at an identical level to the top tread's runs 580, the top of below riser which has at least one aperture, a dowel 205 or a spring-dowel 205,206 to match the slot 208 in the front of and underneath tread 116 to be typically nailed or screwed in a desired precise position.
Top 207 and bottom of risers are nailed or screwed to riser height 570 of stringer at an identical level to the top tread's runs 580, the top of below riser which has at least one aperture, a dowel 205 or a spring-dowel 205,206 to match the slot 208 in the front of and underneath tread 116 to be typically nailed or screwed in a desired precise position. The rear of tread 113 includes a tread radius 118 and a tread groove 119
When the rough and/or decorative stair components are ready to be installed, a reversible universal square 15 could be secured by gluing, nailing or screwing to the inside structural stringer 3 at the back of staircase 500. The universal square 15 underneath the rough tread 18 is set in place and pushed to the back of the riser 17 that is already secured in place. It is significant to install at least two previously described auto adhesive resilient material pieces 15A to the top of the universal square 15 and at least one, if desired, to the middle vertical front of the universal square 15 to be used. This process can be repeated at all triple stringer contacts 3 to the left or right if there are more than 2 structural stringers.
After termination of these operations, all rough treads 18 and risers 17 can be torn-out and ready to receive the new pre-finished or to be finished desired risers 200 and treads 10 to structural stringers 3 and pre-profiled decorative stringers 4. These components can be tighten with suitable appropriated screws from the back of staircase 500 through the reversed taper apertures 215 at the underneath and the back of universal square 15 to the underneath of treads and to the back of the riser. Any nailing and or screwing to top of treads and risers that will be eventually hidden, will be permitted and facilitate the securing of treads and risers from the back of universal squares 15.
When an end-user desires a permanent and solid installation, glue is typically applied to the structural stringers 3 at the suggested grooved shape at tread's runs 580 and/or to the riser's heights 570, top of risers length 207 and/or bottom front riser's grooves 202B to the riser to be tighten to the rear of tread 113 or the rear of tread slot or grooves 119 to be tighten to front bottom of standard riser 200B through the desired pre-drilled apertures 203B at the bottom of the riser with appropriated screws, introduced at the back of the standard riser rear bottom. The typical screws to be used for the staircases' installation are a plurality of rounded head screws 209 that are self-drilled forming angled apertures 208A and tempered of suitable appropriated lengths. (a complete kit of screws needed for the installation of chosen staircase will be available for sale) and other ways to save time and errors.
Standard holder bar (not shown) will come at a plurality of predetermined lengths and typically has the same dimensions as the top of the longer side of the universal square 15 and will be secured at the rear of the universal square 15 when more strength is needed to attach treads to tread's runs of stringer (e.g. Winder's tread 1, 2, 3 to winder's stringers 1001).
Similar suitable techniques to form or drill angled apertures and tapered apertures will be applied as well including securely screwing treads and risers to tread's runs of stringers 580 with a plurality of previously described pieces of sticky and spongy material 15A placed between stringers 580.
Any corner joints 18b, 2542, 2570, cover joints 18c, 2540, 2560, 2585, or starter winder tread plank 101 will be used to hide jointed cuts (good or bad), nails 16 or screws, acting as a recess for pre-profiled and universal skirt board 5, pre-profiled decorative stringers 4, treads 10 and risers 1-200. Some molding with angled overlap 560 will be hid as well, over and at the side of these prefinished or non-prefinished components.
Some pre-shaped inside square cover 13 with or without an inside 502 or an outside radius 702,802,902 can be added to bottom rear tread outside of decorative stringer 4 and/or square angles 602 to match and cover manufactured inside 502 and the bottom shape of rear tread when tread are nosed at side(s).
The pre-shaped inside square cover 13 also includes outside radius 702,802,902 or square angles 602 at the rear and or bottom of lateral overlapped tread's nose.
The pre-shaped inside square cover 13 also includes outside radius 702,802,902 or square angles 602 at the rear and or bottom of lateral overlapped tread's nose.
The pre-shaped inside square cover 13 also includes outside radius 702,802,902 or square angles 602 at the rear and or bottom of lateral overlapped tread's nose.
The back of staircase 500 has to be finished and frequently the professional contractor installer or painter is required to return several times to completely finalize the staircase construction, which can be relatively costly. One way to eliminate this is to supply standard backing panels (not shown) to be adjusted to the back of staircases to be typically equally cut at the jobsite at each side, to be properly fit, pre-finished and fabricated from any suitable material available. The backing panel of staircase can be pre-finished or non-prefinished, plain or with any suitable types of printed, pressure printed, molded designs, grooved or with any suitable designs, textural finish or composition of products adaptable to the back of staircases stringers 3 or 4. Many different types of molding (not shown), shaped or design, can be added to all joints and or walls, floors or ceilings adjacent to staircases. If the stairs, backing panel and moldings are pre-finished, there is no need to have other professionals come back to finalize the construction of the staircase, resulting in a substantial savings of time and money with a relatively more convenient decorative final result. The decorative backing panel of the staircase can be installed with a plurality of nails or a plurality of screws with or without glue with preferably some backing cross-member installed between stringers when necessary and desired sound padding can be added between standard backing panel and back of treads and risers. Any molding should be installed in a floating orientation secured to the wall and should allow for shrinking and expansion variations of structure that do not affect the final aesthetic appearance.
Stringers riser's radius 502 could be disposed on riser rear bottom 131 typically to decorative angled standard risers to assemble with angled decorative stringer's risers' predetermined height and if the height of riser 200 is too wide, the predetermined height of the riser can be cut at a desired height minus radius 502 or at ±15 degrees from the front bottom riser predetermined height. Typically all risers 200 that are installed permanently as standard of any length should be pre-cut at each end at a 45 degrees angle or more and more typically at a 47 degrees angle 590, where the fit with decorative stringer riser height pre-angled cut will be typically suitable and if the riser angle is not necessary can be cut square as needed without creating an inadequate fit.
Some others modifications to risers 200 and treads 10 will attach them at the right position quickly, precisely and tight fit together temporarily and/or permanently (with or without glue) to underneath front of tread 200 A. One of these is, at least one aperture 203A, 203B located at the approximate middle of the top riser length and plus or minus half-thickness of the riser to insert a dowel 205 or preferably a spring 206 plus an appropriated dowel 205 in wood or in other material to the bloc riser at the desired position when dowel 205 is engage in limited slot 208 length at the same distance underneath the tread nose. The dowel 205 is introduced in the slot 208 by the pressure action of the spring pushing the dowel 205. When both the dowel 205 and the slot 208 are connected together, the standard riser 200 is ready to be screwed securely underneath the tread 116 without slipping out of slot, through angled apertures 208A pre-drilled from back of riser 200 B to top of riser with suitable appropriated screws 209. Risers 200 has at least one marker line 201A.
This eliminates steel squares or pre-drilled blocs onsite, usually used by professional contractors. The preferred shapes at the top of the riser should be a W-shaped section
Typically when installers assemble a temporary staircase on a job site are replaced by a decorative staircase, rough treads 18 and risers 200 are nailed to a structural stringer 3, however this is not possible when decorative threads and risers are installed. The staircase 500 remedies this and allows a pre-profiled universal skirt board to be installed at the wall over the nails and/or screws and potential wrong cuts and then be hidden by the thickness of the universal skirt board.
Packing box 2400 is provided to transport any staircase components that need to be protected when carried to the job site. Some components are relatively long such as stringers 3, 4 and the universal skirt board 2631 and are also relatively fragile to carry. More specifically when prefinished, the packaging box 2400 should be solid and very protective and typically is relatively very costly. The packing box 2400 can also have a second use as a cabinet and/or closet with or without a door or a cover 2430 that can also be split into two or more sections 2410 and 2420 that can also be usable as furniture (e.g. a cabinet for tools and accessories or a shoes cabinet open shell) or any other desired suitable utilities or applications, pre-finished or non-pre-finished. The packing box 2400 can potentially save money, prevent environmental waste, as well as protect staircase components to be delivered and serve as a strong marketing tool for a manufacturer, or any intervenient in distribution and sale of staircases and or other domains. The dual purpose packing box 2400 can be adapted to any type of suitable products to be carried needing suitable appropriated protection. The packing box 2400 can be made of any suitable type of material, at any suitable desired dimensions, engineered design, or other needed specification. Different kits of shells, doors and accessories associated with the packing box 2400 will be available on request and can be customized with specified specifications as well.
The back of the staircase 500 is attached to a first wall 2510, a second wall 2520 and a third wall 2530. The back of the staircase 500 is attached between the first wall 2510 and the second wall 2520 and behind a third wall 2530. A skirt board starter joint 2540 attaches the back of the staircase 500 with the third wall 2530 typically at each corner of the back of the staircase 500. There is also a corresponding cap 2542 disposed on each of the skirt board starter joints 2540 to protect the skirt board starter joints 2540. A winder starter plank 2550 attaches the back of the staircase 500 to the first wall 2510. A cap 2552 is also disposed on the winder starter plank 2550 to protect the winder starter plank 2550. A middle skirt board joint 2560 attaches the back of the staircase 500 to the second wall 2520. A cap 2562 is disposed on the middle skirt board joint 2560 to protect the middle skirt board joint 2560. An outside skirt board corner joint 2570 also attaches the back of the staircase 500 to the second wall 2520. A cap 2580 is disposed on the outside skirt board corner joint 2570 to protect the outside skirt board corner joint 2570. A tread rim extender tread 2590 additionally attaches the first wall 2510 to the back of the staircase 500. A tread rim 2595 is disposed underneath the tread rim extender tread 2590 to further attach the back of the staircase 500 to the first wall 2510. A reversible molding 2575 also attaches the back of the staircase 500 to the first wall 2510. A skirt board ender joint 2585 is disposed underneath the reversible molding 2575 to further attach the back of the staircase 500 to the first wall 2510. A cap 2587 is disposed on the skirt board ender joint 2585 to protect the skirt board ender joint 2585.
The staircase 500 includes the reversible molding 2575 which is disposed on top of the staircase 500. There is also a cap 2610 on the top of the staircase 500. The skirt board inside corner joint 2540 is underneath the cap 2610. A tread rim bloc 2620 is disposed underneath the skirt board start joint 2540. A tread rim extender 2630 is vertically and horizontally attached to each vertical portion 2640 of each step 2642 the staircase 500. The tread rim extender 2630 is attached to the vertical portion 2640 with a plurality of screws 2644. The tread rim 2595 is then provided on the distal end 2650 of the horizontal portion 2652 of each step 2642. The universal square 15 secures the vertical portion 2640 and the horizontal portion 2652 together. The overlap angled molding 560 has a pair of ends 562 with a flange 2660 provided on the ends 562 of the overlap angled molding 560. The skirt board ender joint 2585 and cap 2587 are provided at the bottom of the staircase 500.
The structural stringer 3 has a plurality of grooves 2710 disposed on top of the structural stringer 3. The grooves 2710 are typically convex 2712 but can be any suitable shape. The grooves 2710 permit glue to overflow and spill on either side of the grooves 2710 and permit a better and larger grid surface, while also providing a better hold and attachment at the right level. There are one or more tape apertures 2720 provided as well.
The attachment screw 209 includes a threaded portion 2810, a screw head 2820 and a non-threaded portion 2830. The threaded portion 2810 is disposed on a rear half 2802 with a distal end 2803 of the attachment screw 209. The round head 2820 is disposed on a proximal end 2804 of the attachment screw 209. The round head 2820 can be a Phillips head shaped 2822 or any other suitable shaped screw head. The non-threaded portion 2830 is disposed on a front half 2806 of the attachment screw 209 and accommodates a thickness of any tread. There is also a self-drill end 2840 disposed on the end of the distal end 2803. Right now on the market there is not a screw for this application that is more then gage number 9. Gage number 10 or higher may be used in the application.
Installation of the staircase and its components can be done from the top of the staircase to the bottom of the staircase, eliminating the need for an installer to walk on the tread during the installation, which is typically done during the installation. This also allows the installer to work alone without a helper during the installation utilizing a top to bottom installation.
The precision of the structural stringer and the prefabricated components assembled together permit the installation of a prefabricated skirt board after the structural stringer, tread and riser are installed, something that is typically impossible to do with a regular installation with material currently on the market.
Most engineered skirt boards are typically installed in two or three parts because single engineered skirt boards of a suitable length are typically not available and are very difficult to carry and time consuming to manufacture especially with a fit-at-joint assembly. These engineered skirt boards are also less aesthetically attractive than other relatively shorter skirt boards for end-user customers.
In
The packing box will permit the delivery of relatively longer components such as full length skirt boards and full length molding without anxiety regarding the components being broken or damaged while being transported.
There is also a tread groove disposed at the rear of the tread to accommodate any glue spillage and overflow and therefore relatively more glue for a potentially stronger attachment. A plurality of multiple grooves accommodate any glue spillage or overflow that are typically installed at the middle rear portion of the tread that are firmly secured to the riser and tread together to minimize the possibility of glue spillage and overflow over the tread top. The one or more grooves at the top of the riser also have the same function of catching glue spillage and overflow.
Any of the one or more grooves provide a strong, permanent and tight attachment of any adjacent components when the components are made of wholly or partly engineered products, such as OSB, particleboard, fiberboard, plywood, LVL, LSL, softwood and other materials that can easily possibly break, split or allow for a screw or nail to be easily torn-off or removed.
The standard stringer tread support can also be reversible. A plurality of grooves permit glue to overflow and spill on either side of the grooves and permit a better and larger grid surface while also providing a better hold and attachment.
Typically the grooves are disposed around the sides of the stringer that are cut with a shot leveler to lock down, align and set the reversible standard stringer tread support relatively quickly at a desired height and level. Similar to all of the components of the staircase, the grooves disposed around the stringer can be relatively quickly and easily installed.
While the present invention has been related in terms of the foregoing embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described. The present invention can be practiced with modification and alteration within the spirit and scope of the appended claims. Thus, the description is to be regarded as illustrative instead of restrictive on the present invention.
This application claims priority to U.S. Provisional Application 61/374,571 filed on Aug. 17, 2010, the entire disclosure of which is incorporated by reference.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IB11/02659 | 8/17/2011 | WO | 00 | 6/5/2013 |
| Number | Date | Country | |
|---|---|---|---|
| 61374571 | Aug 2010 | US |
