The present disclosure relates to stair systems.
Certain building structures, e.g., a deck or other outdoor structure, may include stairs. However, in certain conventional stair systems, assembly of the stair system can be a resource intensive process and/or can be a highly technical process, which can lead to one or more assembly errors and may result in a defective stair system.
Traditional stair systems suitable for use with outdoor structures are commonly assembled using lumber as a framing material. While the techniques and processes for weather treating lumber have improved over time, the construction process remains a highly technical process that may result in structurally defective systems, aesthetically unpleasing systems, or both defective and unpleasing systems. For example, traditional lumber construction may require relatively precise measurements of multiple angles, multiple relatively precise cuts, and a relatively large number of fasteners.
Accordingly, stair systems for outdoor building structures, such as a deck, are described. Some embodiments of a stair system described herein include a first perimeter frame member and a first stair tread bracket coupled to the first perimeter frame member, when in an assembled configuration. The system also includes one or more stair tread members supported by at least a portion of the first stair tread bracket when in the assembled configuration. The system also includes one or more fastening brackets coupled to the first perimeter frame member, when in the assembled configuration.
The stair tread bracket may include a coupling member and a tread support. The coupling member may be configured to couple to a top side of a perimeter frame member, when in an assembled configuration. Additionally, the stair tread bracket may contact a bottom surface of the one or more stair tread members, when in an assembled configuration.
A fastening bracket may include a first securing surface and a second securing surface. In some embodiments, the first securing surface and the second securing surface are orthogonal to one another, and may be shaped different from one another. The fastening bracket may be coupled to a perimeter frame member at or adjacent a first end of the perimeter frame member, and to a support structure, when in an assembled configuration.
The perimeter frame member may include a first lateral end, a second lateral end that is opposite the first lateral end, a top end, a bottom end that is opposite the top end, and a first side extending between the first lateral end and the second lateral end and extending between the top end and the bottom end. The perimeter frame member also includes a second side opposite the first side, the second side extending between the first lateral end and the second lateral end, and extending between the top end and the bottom end. The first side may include a first and second engagement member, wherein the first engagement member is adjacent the first vertical end, wherein the second engagement member is adjacent the second vertical end, and wherein a recessed portion is positioned between the first and second engagement members.
Illustrative aspects are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein:
Aspects herein relate to stair systems. In certain aspects, the stair systems can be utilized for use with certain building structures, such as a deck or decking system. As discussed above, for certain conventional stair systems, assembly of the stair system can be a resource intensive process and/or can be a highly technical process, which can lead to one or more assembly errors and may result in a defective stair system.
The stair systems disclosed herein can alleviate one or more of the problems described above. For instance, in various aspects, the stair system can include one or more framing members, e.g., a perimeter framing member, which can include one or more structural features described herein that can facilitate interactions between various stair system components. For instance, in one aspect, one or more of the fastening brackets may interact with structural features on the framing members, which allows for increased structural integrity and/or loading, and/or may reduce the load applied to fasteners or other connections. This is unlike certain conventional systems where the structural components may be smooth in shape, which can: place the structural integrity requirements on the fasteners being used to support the structural components; increase installation time (due to the addition of added fasteners and blocking); and allow for misuse of the components. In various aspects, other stair system components can include structural features that can facilitate assembly of the stair system and reduce installation errors. For instance, in various aspects, the stair tread brackets can include a tread support, where, in an assembled configuration, such a tread support may be received in a receiving slot of the one or more stair tread members, which can aid in alignment and/or the securing of the stair tread members to the stair tread bracket and/or to other components of the stair system.
Accordingly, in one aspect, a stair system is provided. The stair system can include a first perimeter frame member; and a first stair tread bracket coupled to the first perimeter frame member, when in an assembled configuration. The stair system can also include one or more stair tread members, where the one or more stair tread members are supported by at least a portion of the first stair tread bracket when in the assembled configuration. The stair system can also include one or more fastening brackets coupled to the first perimeter frame member, when in the assembled configuration.
In yet another aspect, a stair system is provided. The stair system can include a first perimeter frame member; and a second perimeter frame member spaced apart from the first perimeter frame member. The stair system can also include a first stair tread bracket coupled to the first perimeter frame member, when in an assembled configuration; and a second stair tread bracket coupled to the second perimeter frame member, when in an assembled configuration. The stair system can also include one or more stair tread members supported by at least a portion of the first stair tread bracket and the second stair tread bracket, when in the assembled configuration. The stair system can also include one or more first fastening brackets coupled to the first perimeter frame member, when in the assembled configuration; and one or more second fastening brackets coupled to the second perimeter frame member, when in the assembled configuration.
Turning to the figures, and
In the aspect depicted in
In various aspects, the stair system 100 depicted in
In
As discussed above, in certain aspects, other configurations of the stair systems are also contemplated by the disclosure herein, i.e., other stair systems than that described herein with reference to
As mentioned in the preceding paragraph, the middle stair tread bracket 303 provides tread support features on both sides of support wall 303a. This embodiment may facilitate configurations where a first stair tread extends from perimeter frame member 202 to middle stair tread bracket 303 and a second stair tread extends from middle stair tread bracket 303 to perimeter frame member 204. However, embodiments of a middle stair tread bracket can facilitate other configurations. For example, another middle stair tread bracket is depicted in
The support wall 305a, the tread supports 305b and 305c, and the tabs 305d and 305e can function similarly to the respective components of the stair tread members 302a and 304a discussed above. In various aspects, the coupling member 305f is adapted to receive a top portion of a perimeter frame member in a channel 305g with the sides of the coupling member extending down onto both sides of the perimeter frame member. Middle stair tread bracket 305 can be fixed to the perimeter frame member via one or more fasteners using openings 305h, 305i, 305j, or 305k, or a combination thereof.
Additionally, middle stair tread bracket 305 includes groove 3051. Generally, grove 3051 facilitates the use of middle stair tread bracket 305 in multiple configurations of a stair. Said differently, some embodiments of grove 3051 facilitate use with support wall 305a or the intentional removal of the portion of support wall 305a above tread supports 305b and 305c. As such, and similar to middle stair tread bracket 303, inclusion of grove 3051 may facilitate embodiments where a first stair tread extends from perimeter frame member 202 to middle stair tread bracket 305 and a second stair tread extends from middle stair tread bracket 305 to perimeter frame member 204. Additionally, inclusion of grove 3051 may facilitate embodiments where a stair tread extends from perimeter frame member 202 to perimeter frame member 204 while retaining the support provided by middle stair tread bracket 305 via tread supports 305b and 305c.
Groove 3051 extends into the surface of support wall 305a to a predetermined depth. For example, support wall 305a may have a thickness that is measured from the face of support wall 305a that intersects with tread support 305b to the face of support wall 305a that intersects with tread support 305c of about 0.125 inches. In some embodiments, groove 3051 extends to a depth in an inclusive range of 0.06 inches to 0.10 inches. In at least one embodiment, the depth is about 0.063 inches. In at least one embodiment, the depth is 0.063 inches. In at least one embodiment, the predetermined depth is about 0.092 inches. In at least one embodiment, the predetermined depth is 0.092 inches.
Said another way, groove 3051 may be formed by the intentional removal of a portion of the material of support wall 305a. The remaining portion 305m of support wall 305a that is contiguous with groove 3051 may have a thickness in an inclusive range 0.065 inches to 0.025 inches. In at least one embodiment, the thickness of remaining portion 305m is about 0.063 inches. In at least one embodiment, the thickness of the remaining portion 305m is about 0.033 inches.
As depicted, a first portion of groove 3051 may extend along and parallel to the top surface of tread support 305b. A second portion of groove 3051 may extend along and parallel to the top surface of coupling member 305f. The first portion of groove 3051 and the second portion of groove 3051 may merge proximate the point where the top surface of tread support 305b and the top surface of coupling member 305f merge.
Alternatively, in at least one embodiment, the first portion of groove 3051 may extend along and parallel to the top surface of tread support 305c. The second portion of groove 3051 may extend along and parallel to the top surface of coupling member 305f. The first portion of groove 3051 and the second portion of groove 3051 may merge proximate the point where the top surface of tread support 305c and the top surface of coupling member 305f merge.
In the aspect depicted in
In certain aspects, such as that depicted in
As best seen in
While not shown in
In various aspects, to assemble the one or more stair tread members onto a stair tread bracket, a front stair tread member may be first coupled and/or secured to a stair tread bracket. For example, as can be seen in
As used herein the term “about” is used to account for variations in manufacturing tolerances. Accordingly, as used herein about is defined as plus or minus 5% of the stated value in the relevant unit of measure.
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.
Clause 1. A stair system, the stair system comprising: a first perimeter frame member; a first stair tread bracket coupled to the first perimeter frame member, when in an assembled configuration; one or more stair tread members, wherein the one or more stair tread members are supported by at least a portion of the first stair tread bracket when in the assembled configuration; and one or more fastening brackets coupled to the first perimeter frame member, when in the assembled configuration.
Clause 2. The stair system of clause 1, wherein the one or more fastening brackets comprises first and second fastening brackets.
Clause 3. The stair system of clause 2, wherein each of the first and second fastening brackets comprises a first securing surface and a second securing surface, wherein the first securing surface and the second securing surface are orthogonal to one another, and wherein the first securing surface and the second securing surface are shaped different from one another.
Clause 4. The stair system of clause 3, wherein the first fastening bracket is coupled to: the first perimeter frame member at or adjacent a first end of the first perimeter frame member; and to a first support structure, when in an assembled configuration.
Clause 5. The stair system of clause 4, wherein the first securing surface of the first fastening bracket contacts a first side of the first perimeter frame member, and the second securing surface of the first fastening bracket contacts the first support structure, when in the assembled configuration.
Clause 6. The stair system of any of clauses 3-5, wherein the second fastening bracket is coupled to: the first perimeter frame member at or adjacent a second end of the first perimeter frame member; and to a second support structure, when in an assembled configuration.
Clause 7. The stair system of clause 6, wherein the second securing surface of the second fastening bracket is coupled to the first side of the first perimeter frame member, and wherein the first securing surface of the second fastening bracket is coupled to the second support structure, when in an assembled configuration.
Clause 8. The stair system of clause 7, wherein the second securing surface of the second fastening bracket is positioned at least partly within a recessed portion of the first perimeter frame member, when in an assembled configuration.
Clause 9. The stair system of any of clauses 1-8, wherein the first stair tread bracket comprises a coupling member and a tread support.
Clause 10. The stair system of clause 9, wherein the coupling member of the first stair tread bracket is coupled to a top side of the first perimeter frame member, when in an assembled configuration.
Clause 11. The stair system of clause 9 or 10, wherein the tread support of the first stair tread bracket contacts a bottom surface of the one or more stair tread members, when in an assembled configuration.
Clause 12. The stair system of any of clauses 1-11, wherein the one or more stair tread members comprises a front stair tread member and a back stair tread member.
Clause 13. The stair system of clause 12, wherein the front stair tread member is coupled to the back stair tread member via a tab of the front stair tread member and a complementary-shaped receiving tab of the back stair tread member, when in an assembled configuration.
Clause 14. The stair system of any of clauses 1-13, wherein the one or more stair tread members comprise a top surface having one or more recessed portions.
Clause 15. The stair system of any of clause 9-14, wherein the first stair tread bracket further comprises an engagement tab that interacts with an end tab of the one or more stair tread members, when in an assembled configuration.
Clause 16. The stair system of any of clauses 9-15, wherein the one or more stair tread members comprises a receiving slot for receiving at least a portion of the tread support of the first stair tread bracket, when in an assembled configuration.
Clause 17. The stair system of clause 16, wherein the receiving slot of the one or more stair tread members extends from a first side to a second side of the one or more stair tread members.
Clause 18. The stair system of clause 17, wherein the receiving slot of the one or more stair tread members further receives at least a portion of a tread support of a second stair tread bracket, wherein the first stair tread bracket is positioned at the first side of the one or more stair tread members and the second stair tread bracket is positioned at the second side of the one or more stair tread members, when in an assembled configuration.
Clause 19. The stair system of clause 18, wherein the second stair tread bracket is coupled to a second perimeter frame member, wherein the second perimeter frame member is spaced apart from the first perimeter frame member, when in an assembled configuration.
Clause 20. The stair system of any of clause 1-19, wherein the first perimeter frame member comprises a first lateral end; a second lateral end that is opposite the first lateral end; a top end; a bottom end that is opposite the top end; a first side extending between the first lateral end and the second lateral end, and extending between the top end and the bottom end; a second side opposite the first side, the second side extending between the first lateral end and the second lateral end, and extending between the top end and the bottom end; wherein the first side comprises first and second engagement members, wherein the first engagement member is adjacent the first vertical end, wherein the second engagement member is adjacent the second vertical end, and wherein a recessed portion is positioned between the first and second engagement members.
Clause 21. A stair system, the stair system comprising: a first perimeter frame member; a second perimeter frame member spaced apart from the first perimeter frame member; a first stair tread bracket coupled to the first perimeter frame member, when in an assembled configuration; a second stair tread bracket coupled to the second perimeter frame member, when in an assembled configuration; one or more stair tread members supported by at least a portion of the first stair tread bracket and the second stair tread bracket, when in the assembled configuration; one or more first fastening brackets coupled to the first perimeter frame member, when in the assembled configuration; and one or more second fastening brackets coupled to the second perimeter frame member, when in the assembled configuration.
From the foregoing, it will be seen that this invention 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.
This application claims the priority benefit of U.S. Provisional Application No. 63/431,454, titled “Stair System”, filed on Dec. 9, 2022, which is incorporated herein in its entirety.
Number | Date | Country | |
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63431454 | Dec 2022 | US |