Stair component, stair edge nose cover and method

Abstract

A stair component has foundation member including a nose end. Upon attachment of the component to a stair, the nose end projects outwardly from an upper forward edge of the stair. The nose end has a substantially uniform cross-sectional configuration along substantially its entire width. A nose cover having an ornamental exterior surface overlies and covers substantially the entire nose end. The nose cover comprises a thin continuous sheet of preformed plastic having first and second substantially parallel planar portions joined by a curved portion. The foundation member, which may be constructed on site or formed off-site, is adapted to be positioned (a) directly next to a riser portion of the stair so that a vertical support element of the foundation member abuts the riser portion or (b) indirectly so that the vertical support element abuts a secondary vertical member disposed between the foundation member and the riser portion.

Description

DEFINITIONS

The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.

The words “substantially” and “essentially” have equivalent meanings

BACKGROUND

Laminate floor coverings with ornamental exterior surfaces representing wood, tile, stone, and other decorative finishes are very popular. There is, however, a problem installing such coverings on stairs. The accepted manner is to place an edge cover over abutting adjacent edges of flat sheets, one sheet covering an upper stair landing and another sheet covering a vertical riser terminating at one end at the landing. Such edge covers are unsightly and can be dangerous, presenting an obstacle that a person may trip over.

SUMMARY

My stair component, stair edge nose cover and method of laminating a stair have one or more of the features depicted in the embodiments discussed in the section entitled “DETAILED DESCRIPTION OF SOME ILLUSTRATIVE EMBODIMENTS.” The claims that follow define my stair component, stair edge nose cover and method, distinguishing them from the prior art; however, without limiting the scope of my stair component, stair edge nose cover and method of laminating a stair as expressed by these claims, in general terms, some, but not necessarily all, of their features are:

One, my stair component is easily attached to a stair and provides a safe and attractive structure eliminating any obstacle that a person may trip over. It comprises a foundation member and a thin sheet having an ornamental exterior surface overlying and covering substantially a nose end of the foundation member. The nose end may have a substantially uniform cross-sectional configuration along substantially the entire width of the foundation member. This nose end may be rounded, and its entire exterior surface may be substantially covered by the sheet. The foundation member may be constructed on a job site, or it may be formed away from a job site and delivered to the job site for installation. For example, the foundation member may comprise an extruded or molded plastic material.

Two, the foundation member has a predetermined width substantially equal to the width of the stair to which the component is to be attached and a pair of legs. The legs are substantially at a right angle, with one of the legs being adapted to be attached to a riser portion of the stair and the other leg terminating in a nose end projecting outwardly from an upper forward edge of the stair upon attaching the foundation member to the stair. The one leg is adapted to be attached to the riser portion and may be directly attached so that the said one leg abuts the riser portion. Alternately, the one leg is adapted to be attached to the riser portion indirectly so that the said one leg abuts a secondary vertical member disposed between the one leg and the riser portion.

Three, the one leg functions as a vertical support element and the other leg functions as a horizontal support element, each having a predetermined thickness substantially from ½ to 3 inches and a width that is substantially equal to the width of the stair. In addition to these support elements being substantially at a right angle to each other, they are substantially in registration in the width direction. The horizontal support element includes the nose end and a rear end opposite the nose end. The distance from the nose end to the rear end may be substantially from 1 to 4.5 inch. Upon positioning the foundation member next to the riser portion, the rear end of the horizontal support element is substantially flush with a rear side of the vertical support element and the forward rounded nose end extends beyond the front side of the vertical support element substantially from ¾ to 1.5 inch. Also, upon positioning the foundation member next to the riser portion, the vertical support element's front side faces away from the riser portion and a rear side faces toward the riser portion and a bottom edge of the vertical support element is near the lower landing, and a topside of the horizontal support element is substantially flush with the horizontal upper landing.

Four, the thin sheet may be configured into my unique nose cover, which is especially suited for attachment to the foundation member on the job site. The thin sheet, which is originally a substantially flat planar member, is bent into a lazy J configuration, to provide my nose cover. This nose cover includes a thin continuous sheet of preformed plastic having an ornamental exterior surface and opposed substantially parallel side edges spaced apart a distance substantially from 30 to 240 inches. The sheet's thickness is substantially from ⅛ to ¼ inch. The preformed nose cover structure has a first substantially planar portion having a length substantially from 1.5 to 5 inches and terminating in a substantially straight rear edge, a second substantially planar portion having a length substantially from ⅜ to ¾ inch and terminating in a substantially straight rear edge that is inward of the rear edge of the first planar portion, and a curved portion joining the first and second planar portions. The curved portion has a radius of curvature of substantially from ¾ to 1.5 inch. The thin sheet is preformed by heating and forming a substantially flat sheet of plastic into a bent sheet to provide the curved portion joining the first and second planar portions. In other words, the thin sheet has a curved forward end that is preformed to fit snugly over the forward rounded nose end. A second substantially flat thin sheet having an ornamental exterior surface may overly and cover substantially the entire front side of the vertical support element.

My method comprises (a) attaching a foundation member to the stair, the foundation member having a nose portion that projects outwardly from an upper forward edge of the stair upon attaching the foundation member to the stair, and (b) covering with a thin sheet having an ornamental exterior surface substantially the entire nose end. The nose portion extends at least ¾ inch outward from a riser portion of the stair.

These features are not listed in any rank order nor is this list intended to be exhaustive.

DESCRIPTION OF THE DRAWING

Some embodiments of my stair component, stair nose cover and method of laminating a stair are discussed in detail in connection with the accompanying drawing, which is for illustrative purposes only. This drawing includes the following figures (Figs.), with like numerals indicating like parts:

FIG. 1A is a perspective view of a conventional laminated stair.

FIG. 1 is a perspective view of one embodiment of my nose cover.

FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1.

FIG. 3 is a cross-sectional view of a foundation member of my stair component shown attached to a wooden stair structure.

FIG. 3A is a cross-sectional view of one embodiment of my stair component having its foundation member attached to a concrete stair structure.

FIG. 3B is a fragmentary cross-sectional view of another embodiment of my stair component.

FIG. 4 is a perspective view of another embodiment of a foundation member of my stair component.

FIG. 4A is a cross-sectional view taken along line 4A-4A of FIG. 5.

FIG. 5 is a cross-sectional of yet another embodiment of a foundation member of my stair component.

DETAILED DESCRIPTION OF SOME ILLUSTRATIVE EMBODIMENTS

FIG. 1A

A conventional stair is illustrated in FIG. 1A where the stair is covered with thin laminate sheets having an ornamental exterior surface ES. Mannington, Inc., for example, provides suitable laminate sheets with adhesive on one side. The sheets overlie and cover substantially the entire upper landing UL, lower landing LL, and riser portion RP of the stair, and their undersides (not shown) are typically bonded to the stair's surfaces with an adhesive. In typical applications, the upper landing UL has a width w substantially from 30 to 240 inches, and the riser portion RP of the same width and a height h substantially from 3 to 8 inches. The upper landing UL and riser portion RP form a sharp 90° corner, and the adjacent sheets on the upper landing UL and riser portions RP have abutting edges AE that an L-shaped edge cover EC overlaps. This edge cover EC may be an extruded metal such as aluminum and attached by screws 10, or it may be of rubber or plastic and glued or otherwise held in place. This is an unattractive and unsafe way to cover the abutting edges AE.

FIGS. 1 through 5

One embodiment of my stair edge nose cover NC is depicted in FIGS. 1 through 3; a second embodiment is depicted in FIGS. 3A and 3B; a third embodiment is depicted in FIGS. 4 and 4A and a forth embodiment is depicted in FIG. 5. A foundation member FM constructed on the job site is fastened directly to a riser portion RP of a stair as illustrated in FIG. 3, or indirectly to the riser portion RP using a supplemental foundation member in the form of a vertical member 30 as illustrated in FIG. 3A. One alternate embodiment of a foundation member is identified as FM2 in FIGS. 4 and 4A, and another alternate embodiment of the foundation member is identified as FM3 in FIG. 5.

As best illustrated in FIG. 3, all the foundation members FM, FM2 and FM3 include a nose portion 40 that my nose cover NC overlies and fits snugly against, being bonded to an exterior surface of the nose portion by an adhesive. The combination of one of the foundation members FM or FM2 or FM3 and my nose cover NC forms my stair component. Upon attachment of the stair component to a stair, the nose portion 40 projects outwardly from an upper forward edge of the stair as best depicted in FIG. 3A. The nose portion 40 has a substantially uniform cross-sectional configuration along substantially its entire width, which is substantially equal to the width w of the stair. The nose portion 40 has a rounded forward surface at its nose end NE. The nose end NE extends at least ¾ inches outward from the riser portion RP of the stair.

As shown in FIGS. 1, 2 and 3A, my nose cover NC is a laminate sheet having an ornamental exterior surface ES, and it is a continuous sheet of preformed plastic with a thickness substantially from ⅛ to ¼ inch and opposed substantially parallel side edges ED1 and ED2 spaced apart a distance d1. My nose cover NC may be an integral structure where the distance d1 may be substantially equal width w of the stair, or it may comprises sections abutted together. As shown in FIG. 2, it includes a first substantially planar portion PP1 having a length I₁ substantially from 1.5 to 5 inches that terminates in a substantially straight rear edge ED 3 that is substantially at a right angle to the side edges ED1 and ED2, and a second substantially planar portion PP2 having a length I₂ substantially from ⅜ to ¾ inches that terminates in a substantially straight rear edge ED4 that is inward of the rear edge ED3 of the first planar portion. The inner ends E1 and E2 respectively of the first and second planar portions PP1 and PP2 are aligned and opposite each other, and a curved portion CP integral with these inner ends joins the planar portions. The curved portion CP may be a segment of a circle having a radius of curvature R of substantially from ¾ to 1.5 inch. The center C1 of the curved portion CP is substantially equidistant from the inner ends E1 and E2 and alone a line intersecting the ends E1 and E2. The laminate sheet forming the nose cover NC is typically a vinyl plastic preformed by heating and forming a substantially flat laminate sheet into a bent sheet to provide the curved portion CP joining the first and second planar portions PP1 and PP2.

The foundation members FM, FM2 and FM3 each includes substantially vertical and horizontal support elements upon installation, each element has a predetermined thickness substantially from ½ to 3 inches. The elements may be made of one or multiple plywood planks as in the case of the foundation member FM, or as in the case of the foundation members FM2 and FM3, they may be integral elements that provide a rigid, unitary structure formed of a tough plastic material during a manufacturing process such as extrusion or molding. A suitable plastic material is, for example, ABS resin. The foundation members FM, FM2 and FM3 are substantially identical in overall external configuration and dimensions when being used with a particular stair and are interchangeable. They differ in that the foundation members FM2 and FM3 are performed and are delivered to a job site, whereas the foundation member FM is constructed on the job site. The foundation member FM2 is solid and the foundation member FM3 has hollow portions (FIG. 5) extending along its length (d1) and an upper a row of apertures 80a passing through its nose portion 40 and a lower a row of apertures 80b passing through its leg L2. Both embodiments FM2 and FM3 include a linear, channel 82 on its backside horizontally oriented upon installation. Both foundation members FM2 and FM3 may come in different lengths and/or heights.

In the foundation member FM the planks are placed in registration with each other at right angle to form an inverted letter “L” configuration as shown in FIG. 3. The planks are of equal length, being each equal to the width w of the stair. One plank forms a leg L1 (FIG. 3) and the other plank forms a leg L2. When the foundation member FM is positioned next to the riser portion RP, the leg L2 forms a substantially vertical support element VE and the leg L1 forms a substantially horizontal support element HE. The leg L2, that is, the vertical support element VE, has a thickness t substantially from ⅝ to ¾ inches, a front side FS and a rear side RS, a top edge TE and a bottom edge BE. The height h2 of the leg L2 is substantially from 3 to 8 inches. The leg L1, that is, the horizontal support element HE, has a height h substantially from ¾ to 2 inches and a length I₃ substantially from 1 to 4.5 inches, the forward rounded nose end NE, a substantially vertical rear end RE, a topside TS and a bottom side BS.

Upon positioning the foundation member FM next to the riser portion RP, the rear end RE of the horizontal support element HE is substantially flush with the rear side RS of the vertical support element VE. Additionally, upon positioning the foundation member FM next to the riser portion RP, the vertical support element's front side FS faces away from the riser portion and the rear side RS faces toward the riser portion and the bottom edge BE of the rests on the lower landing LL and the top edge TE is below the upper landing UL, and the topside TS of the horizontal support element HE is substantially flush with the top surface of the upper landing UL. A substantially flat thin laminate sheet 50 (FIG. 3A) having an ornamental exterior surface may overlie and cover substantially the entire front side FS of the vertical support element VE and be bonded thereto by an adhesive.

According to my method of laminating a stair, the foundation member FM is first put in position next to the stair. The foundation member FM may be positioned next to the riser portion RP directly so that the vertical support element VE of the foundation member FM abuts the riser portion, or indirectly so that the vertical support element abuts a secondary vertical member 30 (FIG. 3A), i. e. the supplemental foundational member, disposed between the foundation member FM and the riser portion RP. The nose portion 40 now projects outwardly from an upper forward edge of the stair, and it is covered my stair edge nose cover NC, which is bonded to the nose portion's exterior surface. The nose cover NC is typically bonded to the nose portion 40 after the foundation member FM is positioned next to the stair. The forward rounded nose end NE extends a distance d2 (FIG. 3A) beyond the riser portion RP substantially from 1 to 1.5 inches, including the vertical support element VE and any secondary vertical member 30, if needed.

In FIG. 3 the foundation member FM is depicted in a position directly next to the riser portion RP so that the vertical support element VE of the foundation member FM abuts the riser portion. As shown in FIG. 3A, the foundation member FM is positioned next to the riser portion RP indirectly so that the vertical support element VE abuts a secondary vertical member 30, for example another plywood plank, disposed between the foundation member FM and the riser portion. The horizontal support element HE may be fastened in place by wood screws 60 spaced apart at about 6 to 8 inch intervals. The wood screws 60 extend into and though the nose end NE and into either wooden stair structure or the secondary vertical member 30. This fastens the horizontal support element HE firmly in place. The nose cover covers an exposed head of the screw 60. In the embodiment shown in FIG. 3, a pair of screws 62 fastens the vertical support element VE to the wooden stair structure. The nose end NE of the horizontal support element HE has an edge ED 8 (FIG. 3) extends beyond the front side FS of the vertical support element VE a distance d5 substantially from ¾ to 1.5 inch. In the embodiment shown in FIG. 3A, a concrete anchor A passes through the secondary vertical member 30 to hold this secondary member firmly against the riser portion RP of a concrete stair. The pair of screws 62 fastens the vertical support element VE to the secondary vertical member 30 disposed between the foundation member FM and the riser portion RP of the stair.

The edge ED3 of the nose cover NC terminates at the rear end RE of the horizontal support element HE and abuts a straight edge ED5 of a laminate sheet 70 (FIG. 3A) covering the upper landing UL. When the secondary vertical member 30 is employed, the laminate sheet 70 overlaps and covers the top edge ED6 of the secondary vertical member. The bottom edge ED7 the secondary vertical member 30 rests against the lower landing LL. The edge ED4 of the planar portion PP2 abuts the front side FS of the vertical support element VE. As illustrated in FIG. 3B, a laminate sheet 50a may be applied to the vertical support element VE prior to assembly of the foundation member FM and cover this element's entire front surface FS. In this case, then the edge ED4 abuts this laminate sheet 50a.

Using my method produces a step having a rounded nose portion projecting outward from an upper forward edge of the step's upper landing to extend beyond the step's riser portion beneath the underside of the step's upper landing. This may be accomplished by the use of the foundation members FM, FM2 and FM3 as discussed above to retrofit a stair that has its riser portion RP flush with the upper landing UL to form a shape 90° corner along the upper forward edge of the upper landing UL. Alternately, the upper landing itself may be constructed with a nose portion extending beyond a riser portion that is offset inward from the step's upper forward edge and is beneath the underside of the upper landing. In both cases, the upper landing UL is covered with the laminate sheet 70, which has a predetermined ornamental exterior surface, for example, a series of vinyl wood planks And in both cases, the nose portion projects outward from the upper forward edge of the upper landing to extend beyond the riser portion that is beneath an underside of the upper landing. The nose portion is rounded along its entire length and my nose cover NC is curved to conform to the rounded surface of the nose portion to fit snug against it when applied thereto. Simply bending a laminate sheet at a 90° angle and applying it to the 90° corner would be unsatisfactory, because a 90° bend would crack the laminate sheet either immediately or within a short period of use. The curved portion CP in my nose cover NC avoids this potential problem.

In accordance with one embodiment, my nose cover NC is a second laminate sheet having essentially the same predetermined ornamental exterior surface as the laminate sheet 70. Thus, there are matching ornamental exterior surfaces on the step's upper landing and the upper forward edge of the step's upper landing. This creates a desirable aesthetic effect. The step's riser portion may also be covered with a third laminate sheet that has essentially the same predetermined ornamental exterior surface as the nose cover NC and the sheet 70. In this case, the vertical support element VE is considered an integral part of the riser portion, and this riser portion's exterior surface may be covered with a laminate sheet having essentially the same predetermined ornamental exterior surface as the nose cover NC and the sheet 70. This further enhances the desirable aesthetic effect. Moreover, this step structure, avoiding the use of the L-shaped edge cover EC, is inherently safer than a conventional step having its upper landing and riser portion covered by laminate sheets as depicted in FIG. 1A.

The foundation members FM2 and FM3 are positioned in a similar manner as the foundation member FM in FIG. 3 directly against and abutting the riser portion RP of the stair and may be held in position by an adhesive applied to the channel 82. In the case of the foundation member FM3, it is molded in order to form rows of apertures 80a and 80b in the body of this foundation member. Fasteners such as screws are inserted through the apertures 80a and 80b into the stair's riser RP directly. Alternately, the member FM2 or the member FM3, as the case may be, is positioned in a similar manner next the vertical member 30 as shown in FIG. 3A, and fastened thereto as discussed above.

SCOPE OF THE INVENTION

The above presents a description of the best mode I contemplate of carrying out my stair component, nose cover and of the manner and method of making and using them, in such full, clear, concise, and exact terms as to enable a person skilled in the art to make and use. My stair component, nose cover and method are, however, susceptible to modifications and alternate constructions from the illustrative embodiments discussed above which are fully equivalent. Consequently, it is not the intention to limit my stair component, nose cover and method to the particular embodiments disclosed. On the contrary, my intention is to cover all modifications and alternate constructions coming within the spirit and scope of my stair component, nose cover and method as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of my invention:

Claims

1. A stair component for attachment to a stair comprising a foundation member having a predetermined width substantially equal to the width of the stair to which the component is to be attached and a pair of legs substantially at a right angle with one of the legs being adapted to be attached to a riser portion of the stair and the other leg terminating in a nose end that projects outwardly from an upper forward edge of the stair upon attaching the foundation member to the stair,said nose end having a substantially uniform cross-sectional configuration along substantially the entire width of the foundation member and being covered with a thin sheet having an ornamental exterior surface overlying and covering the nose end.

2. The stair component of claim 1 where the nose end is rounded and its entire exterior surface is substantially covered.

3. The stair component of claim 1 where the foundation member is constructed on a job site.

4. The stair component of claim 1 where the foundation member is formed away from a job site and delivered to the job site for installation.

5. The stair component of claim 4 where the foundation member comprises an extruded plastic material.

6. The stair component of claim 4 where the foundation member comprises a molded plastic material with apertures therein.

7. A stair component for attachment to a stair comprising a foundation member including a nose end that projects outwardly from an upper forward edge of the stair upon attaching the foundation member to the stair,said nose end being covered with a thin sheet having an ornamental exterior surface overlying and covering the nose end, said nose end being rounded and its entire exterior surface being substantially covered by said thin sheet.

8. A stair edge nose cover comprising a thin continuous sheet of preformed plastic having an ornamental exterior surface andopposed substantially parallel side edges spaced apart a distance substantially from 30 to 240 inches,a thickness substantially from ⅛ to ¼ inch,a first substantially planar portion having a length substantially from 1.5 to 5 inches and terminating in a substantially straight rear edge,a second substantially planar portion having a length substantially from ⅜ to ¾ inch and terminating in a substantially straight rear edge that is inward of the rear edge of the first planar portion, anda curved portion joining the first and second planar portions, said curved portion having a radius of curvature of substantially from ¾ to 1.5 inch.

9. The stair edge nose of claim 8 where the sheet is preformed by heating and forming a substantially flat sheet of plastic into a bent sheet to provide the curved portion joining the first and second planar portions.

10. A stair component for attachment to a stair having a predetermined width, a substantially horizontal upper landing, and a riser portion having predetermined height extending from a substantially horizontal lower landing to the upper landing, said stair component comprising a foundation member adapted to be positioned next to the riser portion and including substantially vertical and horizontal support elements, each element having a predetermined thickness substantially from ½ to 3 inches and a width that is substantially equal to the width of the stair, said support elements being substantially at a right angle to each other and substantially in registration in the width direction,said vertical support element having a front side and a rear side, and a bottom edge,said horizontal support element includes a forward rounded nose end, a rear end, a topside, and distance from the nose end to the rear end is substantially from 1 to 4.5 inch,upon positioning the foundation member next to the riser portion, the rear end of the horizontal support element is substantially flush with the rear side of the vertical support element and the forward rounded nose end extends beyond the front side of the vertical support element substantially from ¾ to 1.5 inch,upon positioning the foundation member next to the riser portion, the vertical support element's front side faces away from the riser portion and the rear side faces toward the riser portion and the bottom edge of the vertical support element is near the lower landing, and the topside of the horizontal support element is substantially flush with the horizontal upper landing,a first thin sheet having an ornamental exterior surface overlying and covering substantially the entire forward rounded nose end and topside of the horizontal support element, said first thin sheet having a curved forward end that is preformed to fit snugly over the forward rounded nose end of the horizontal support element, anda second substantially flat thin sheet having an ornamental exterior surface overlying and covering substantially the entire front side of the vertical support element.

11. The stair component of claim 10 where a fastening member extends into and though the nose end to hold the stair component in position, said first thin sheet covering any exposed portion of the fastening member.

12. The stair component of claim 10 where a secondary vertical support element is disposed between the foundation member and the riser portion of the stair.

13. The stair component of claim 10 where the foundation member consists essentially of wood.

14. The stair component of claim 10 where the foundation member consists essentially of plastic.

15. The stair component of claim 10 where the first thin sheet has an upper portion that is bonded to the topside of the horizontal support element and terminates in a first edge that is inward of the nose end and a lower portion that terminates in a second edge that is inward of the nose end and abuts the front side of the vertical support element.

16. The stair component of claim 15 where the first edge is substantially adjacent to the vertical rear end of the horizontal support element or projects inward.

17. The stair component of claim 10 where the foundation member is adapted to be positioned next to the riser portion directly so that the vertical support element abuts the riser portion.

18. The stair component of claim 10 where the foundation member is adapted to be positioned next to the riser portion indirectly so that the vertical support element abuts a secondary vertical member disposed between the foundation member and the riser portion.

19. A method of laminating a stair comprising the steps of (a) attaching a foundation member to the stair, said foundation member having a nose portion that projects outwardly from an upper forward edge of the stair upon attaching the foundation member to the stair, and(b) covering with a thin sheet having an ornamental exterior surface substantially the entire nose end.

20. The method of claim 19 where the nose portion has a rounded forward surface and extends at least ¾ inch outward from a riser portion of the stair.

21. The method of claim 20 where the foundation member is positioned next to the riser portion directly so that a vertical support element of the foundation member abuts the riser portion.

22. The method of claim 20 where the foundation member is positioned next to the riser portion indirectly so that a vertical support element of the foundation member abuts a secondary vertical member disposed between the foundation member and the riser portion.

23. A step comprising an upper landing covered with a first laminate sheet having a predetermined an ornamental exterior surface,said upper landing having a rounded nose portion projecting outward from an upper forward edge of the upper landing to extend beyond a riser portion that is beneath an underside of the upper landing,said nose portion being covered with a second laminate sheet having essentially the same predetermined ornamental exterior surface as the first sheet.

24. The step of claim 23 where the nose portion extends at least ¾ inch outward from the riser portion.