U.S. patent application number 09/840640 was filed with the patent office on 2004-02-05 for prefabricated stairway and method.
Invention is credited to Kress, Russell L..
Application Number | 20040020142 09/840640 |
Document ID | / |
Family ID | 46298759 |
Filed Date | 2004-02-05 |
United States Patent
Application |
20040020142 |
Kind Code |
A1 |
Kress, Russell L. |
February 5, 2004 |
Prefabricated stairway and method
Abstract
A fiber reinforced plastic stairway has a pair of laterally
spaced apart elongated stringers adapted to be disposed between
levels of the building and a plurality of integral riser surfaces
and integral tread surfaces extending between said stringers so as
to form steps. A plurality of individual preformed tread members
are fastened on the tread surfaces.
Inventors: |
Kress, Russell L.; (Rowley,
IA) |
Correspondence
Address: |
Mr. Edward J. Timmer
Walnut Woods Centre
5955 W. Main Street
Kalamazoo
MI
49009
US
|
Family ID: |
46298759 |
Appl. No.: |
09/840640 |
Filed: |
April 24, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09840640 |
Apr 24, 2001 |
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09711854 |
Nov 13, 2000 |
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6543191 |
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Current U.S.
Class: |
52/185 ;
52/182 |
Current CPC
Class: |
E04F 11/17 20130101;
E04F 2011/0212 20130101; E04F 2011/0218 20130101; E04H 4/144
20130101; E04F 11/02 20130101 |
Class at
Publication: |
52/185 ;
52/182 |
International
Class: |
E04F 011/00; E04F
019/10 |
Claims
I claim:
1. Stairway, comprising a pair of laterally spaced apart elongated
stringers adapted to be disposed between levels of the building and
a plurality of integral riser surfaces and integral tread surfaces
extending between said stringers so as to form steps, said
stringers, riser surfaces and tread surfaces being formed as
one-piece of plastic material.
2. The stairway of claim 1 including a plurality of individual
preformed tread members fastened on the tread surfaces.
3. The stairway of claim 1 including a joist attachment member
disposed in a laterally extending channel formed integrally on the
rear side of a topmost riser surface between the stringers.
4. The stairway of claim 3 wherein said fastening member is a
wooden member received in said channel.
5. The stairway of claim 3 wherein said channel is formed in-situ
about said fastening member.
6. The stairway of claim 1 wherein each stringer includes a first
upstanding wall and a laterally extending wall.
7. The stairway of claim 6 wherein said laterally extending wall
includes receptacles formed integrally therein to receive handrail
support posts.
8. The stairway of claim 6 wherein each stringer further includes a
second upstanding wall extending upwardly from said laterally
extending wall.
9. The stairway of claim 6 wherein each stringer further includes
an outermost wall that extends downwardly from said laterally
extending wall.
10. The stairway of claim 9 wherein a cover panel is fastened to a
lowermost edge of said outermost wall.
11. The stairway of claim 6 wherein a reinforcing gusset is
disposed between said first upstanding wall and said laterally
extending wall.
12. The stairway of claim 1 wherein said plastic material comprises
one or more outer filled resin layers and one or more inner fiber
reinforced filled resin layers applied on the outer filler resin
layer(s).
13. The stairway of claim 12 wherein said one or more outer filled
resin layers each comprises a synthetic resin and mineral particles
and said one or more inner fiber reinforced resin layers each
comprises a resin, mineral particles and chopped fibers.
14. The stairway of claim 1 wherein said tread surfaces are
configured to include an integral reinforcement.
15. The stairway of claim 14 wherein said integral reinforcement
comprises a rib extending along a length of each tread surface and
having a concave cross-sectional configuration residing below a
plane defined by said tread surface.
16. The stairway of claim 2 wherein said preformed tread members
comprise an outer ceramic filled gelcoat layer and a fiber
reinforced filled resin layer under said gelcoat layer.
17. The stairway of claim 2 wherein said preformed tread members
include an integral bull nose that depends downwardly to overlap
the adjacent riser surface located therebelow.
18. The stairway of claim 2 wherein said preformed tread members
include a plurality of fasteners and said tread surface includes a
plurality of holes to receive a respective fastener.
18. The stairway of claim 18 wherein a lower surface of each said
preformed tread member includes a plurality of pilot protrusions
that are received in a respective one of said holes in said
underlying tread surface.
20. The stairway of claim 18 wherein said fasteners include an
enlarged fastener head captured in each tread member and a threaded
shank received in a respective hole of said tread surface.
21. The stairway of claim 18 wherein said fasteners each include an
enlarged fastener head captured in said landing member and a
threaded shank received in a respective hole of said landing
surface.
22. In a building having an upper level and a lower level, a
prefabricated stairway disposed between said levels and comprising
a pair of laterally spaced apart elongated stringers fastened at an
upper region to a joist of said upper level and a plurality of
integral riser surfaces and integral tread surfaces extending
between said the stringers so as to form steps, said stringers,
riser surfaces and tread surfaces being formed as one-piece of
plastic material.
23. The stairway of claim 22 including a plurality of individual
preformed tread members fastened on the tread surfaces.
24. The stairway of claim 22 including a joist attachment member
disposed in a laterally extending channel formed integrally on the
rear side of a topmost riser surface between the stringer
sections.
25. The stairway of claim 24 wherein said attachment member is a
wooden member received in said channel and fastened to said
joist.
26. A method of making a stairway, comprising spraying plastic
material on a mold surface to form a one-piece stairway comprising
a pair of laterally spaced apart stringers and a plurality of
integral riser surfaces and integral tread surfaces forming steps,
independently forming a plurality of preformed tread members, and
fastening a respective one of said preformed tread members on a
tread surface of said stairway.
27. The method of claim 26 wherein said plastic material comprises
an outer filled resin layer is provided on said mold followed by
providing a plurality of fiber reinforced filled resin layers on
said filled resin layer.
28. The method of claim 27 wherein said outer filled resin layer
comprises a synthetic resin and mineral particles and said inner
fiber reinforced resin layer comprises a resin, mineral particles
and chopped fibers.
29. Combination of a stairway having a plurality of treads made of
a material selected from the group consisting of wood, metal, and
concrete and at least one preformed tread member comprising plastic
material fastened on at least one tread.
30. The combination of claim 29 wherein the tread member has a
color that is different from the steps.
31. The combination of claim 29 wherein the tread member is
fastened on a worn or damaged tread of said stairway.
32. A method of repairing a worn or damaged tread of a stairway
made of a material selected from the group consisting of wood,
metal, and concrete by fastening a preformed tread member
comprising plastic material on said tread.
Description
[0001] This application is a continuation-in-part of Ser. No.
09/711,854 filed Nov. 13, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates to a prefabricated, plastic
stairway for use between levels (e.g. floors and landings) of a
building or other structure.
BACKGROUND OF THE INVENTION
[0003] A common technique for fabricating a stairway between floors
of a building, such as a residential home, involves fastening
wooden stringers by nails and/or brackets to floor joists and
nailing wooden treads and wooden risers between the stringers to
form a plurality of steps. The stringers can be fastened to the
floor joist first followed by fastening of the treads and risers to
the stringers, or the stringers and treads/risers can be fastened
together to form a heavy stairway unit that must then be moved into
position and fastened to the floor joists.
[0004] An object of the present invention is to provide an improved
prefabricated stairway for use between floors and landings of a
building or other structure where the stairway is relatively
lightweight, requiring no special equipment to facilitate transport
and proper positioning at the building or structure site, and yet
sturdy enough to withstand loads encountered in use, is resistant
to wear and chemicals, and offers improved stairway aesthetics.
SUMMARY OF THE INVENTION
[0005] The present invention provides in one embodiment a
prefabricated stairway comprising a pair of laterally spaced apart
elongated stringers adapted to be disposed between levels (e.g.
floors and landings) of the building and a plurality of integral
riser and tread surfaces extending between the stringer sections so
as to form steps. The stringers, riser surfaces and tread surfaces
are formed integrally of a plastic material. A plurality of
individual preformed tread members are fastened on the tread
surfaces. The tread members can be made of plastic material, wood,
metal and other materials. The stairway can include an optional
landing surface and landing member fastened on the landing surface
proximate the top and/or bottom of the stairway.
[0006] The prefabricated stairway preferably includes a joist
attachment member disposed in a laterally extending channel formed
integrally on the rear side of the topmost riser surface between
the stringers. The joist attachment member is thereby incorporated
into the stairway and adapted to receive fasteners, such as a lag
bolts, by which the stairway is fastened to a joist of a building
floor or landing.
[0007] The prefabricated stairway optionally can include
receptacles formed integrally along the lengths of the stringers to
receive ballaster posts and newel posts of a handrail.
[0008] The prefabricated stairway preferably comprises one or more
outer filled resin layers and one or more inner fiber reinforced,
filled resin layers applied on the outer filler resin layer(s).
[0009] In a preferred embodiment of the invention, the tread
surfaces are configured to include an integral reinforcement
surface region, such as an integral reinforcement rib extending
along a length of each tread surface. The reinforcement rib has a
concave cross-sectional configuration residing below a plane
defined by the respective tread surface and the landing surface.
The preformed tread members preferably comprise of an outer ceramic
filled gelcoat layer and one or more fiber reinforced, filled resin
layers and are attached to the respective tread surfaces using
fasteners. The fasteners preferably are captured in part in each
tread member and optional landing member during molding so as to be
integral therewith.
[0010] Another embodiment of the invention envisions fastening one
or more tread members to one or more steps of an existing stairway
made of wood, concrete, metal and other materials. One or more
tread members can be fastened to refurbish one or more worn or
damaged steps. One or more colored thread members can be fastened
to one or more steps to enhance the visual appearance of the
step(s).
[0011] The above and other objects and advantages of the invention
will become apparent from the following detailed description taken
with the following drawings.
DETAILED DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an elevational view, partially in section, of a
stairway pursuant to an embodiment of the invention.
[0013] FIG. 2 is a sectional view of the stairway taken along lines
2-2 of FIG. 1.
[0014] FIG. 3 is a sectional view of the stairway taken along lines
3-3 of FIG. 1.
[0015] FIG. 4 is a partial plan view of the stairway.
[0016] FIG. 5 is an elevational view, partially in section, of the
stairway showing the tread members with integral fasteners.
[0017] FIG. 6 is an enlarged exploded partial cross-sectional view
of the tread surface and tread member.
[0018] FIG. 7 is an enlarged partial cross-sectional view of the
sprayed plastic wall of the stairway.
[0019] FIG. 8 is a side elevation of the stairway after the tread
members are fastened on the tread surfaces.
[0020] FIG. 9 is a front elevation, partially in section, of the
stairway installed in a stairwell showing wall studs and a
handrail.
[0021] FIG. 10 is an elevational view, partially in section, of a
free-standing stairway pursuant to another embodiment of the
invention.
[0022] FIG. 11 is a plan view of the stairway of FIG. 10.
[0023] FIG. 12 is an elevational view, partially in section, of the
free-standing stairway of FIG. 12 showing ballaster posts and newel
posts received in receptacles of the stairway.
[0024] FIG. 13 is a sectional view of the stairway taken along
lines 13-13 of FIG. 10.
[0025] FIG. 14 is a sectional view of a preformed tread member on a
wooden step.
[0026] FIG. 15 is a sectional view of a preformed tread member on a
concrete step.
[0027] FIG. 16 is a sectional view of a preformed tread member on a
metal step.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring to FIGS. 1-9, a prefabricated stairway 10 pursuant
to one illustrative embodiment of the invention is shown to
illustrate the invention but not limit the scope of the invention.
The stairway 10 is illustrated as comprising a pair of laterally
spaced apart elongated stringers 12 adapted to be disposed between
levels of the building, such as for example between an upper floor
and a lower floor or between a floor and a landing, and vice versa,
as may be present in a split level home, and a plurality of
integral riser surfaces 14 and integral tread surfaces 16 extending
between the stringers 12 so as to form steps. Each stringer 12
includes an upstanding lower wall 12a, a laterally extending wall
12b and a second upstanding upper wall 12c. The stringer walls 12a,
12b are connected by integral reinforcing gusset 15 proximate the
intersection of each riser surface 14 and tread surface 16. A
plurality of individual preformed tread members 18 are fastened on
the tread surfaces 16 as shown in FIGS. 5-6 and 8.
[0029] The prefabricated stairway is shown including a joist
attachment member 20 disposed in a laterally extending channel 22
formed integrally on the rear side of the topmost riser surface 14,
FIG. 1. The topmost tread surface 16 above the channel 22 may be
shortened in depth d compared to the other tread surfaces 16 so
that the topmost tread surface is closely spaced to or abuts the
floor 30. A correspondingly shortened tread member 18 is fastened
on the topmost tread surface 16.
[0030] The joist attachment member 20 and channel 22 extend between
the stringers 12. The channel 22 is formed integrally with the
stringers 12 with the joist attachment member 20 incorporated
in-situ in the channel 22 during the molding process described
below. The joist attachment member 20 thusly is incorporated into
the stairway 10 as an integral part thereof. The joist attachment
member 20 can comprise conventional 2.times.4 lumber (2.times.4
stud) having a length to extend in channel 22 between the walls 12a
of the stringers 12. The channel 22 includes top and bottom walls
22a, 22b, rear wall 22c, and a front wall that is formed by the
rear side of the topmost riser surface 14.
[0031] The joist attachment member 20 is adapted to receive
fasteners, such as lag bolts 25 (one shown), along its length by
which the stairway 10 is fastened to a wooden floor or landing
joist J as shown in FIG. 1. The lag bolts 25 extend through the
floor or landing joist J into the attachment member 20. The channel
22 can be drilled through its rear wall 22c to provide holes to
receive the lag bolts. The invention is not limited to a joist
attachment member 20 made of wood and can be practiced using an
attachment member 20 made of plastic material, composite material
and others. The attachment member 20 and channel 22 can be formed
as a one molded solid integral member. The floor joist J shown can
comprise conventional 2.times.8 or 2.times.12 lumber used in
construction and support of the floor 30 of a building, such as a
residential home. The floor 30 is shown comprising a sub-floor 30a
and finished floor 30b pursuant to conventional floor construction
practice. The joist J is not limited to the lumber described since
the floor or landing joist can comprise other types and sizes of
lumber, engineered lumber, steel beams, and any other member used
as a floor joist.
[0032] As shown in FIG. 9, the upper region of the stringers 12
also can be fastened to wall studs WS by screws 34 extending
through wall 12c of each stringer 12 into the wall studs. The wall
studs typically are used to form a stairwell to receive the
stairway 10.
[0033] As shown in FIG. 1, the lower end of the stairway 10 rests
on the lower floor 35, which may comprise a basement floor, a first
floor when floor 30 is a second floor, a second floor when floor 30
is a third floor and so on, or a landing of a split level home. As
shown in FIG. 9, the lower end of the stairway 10 optionally can be
fastened in position to wall studs WS by fasteners, such as screws
34, that extend through the wall portion 12c of each stringer 12.
Holes can be drilled through the wall 12c, countersunk, and
centered on the wall studs to receive the screws 34 to this
end.
[0034] The tread surfaces 16 are generally flat and horizontal with
the exception that they are configured to include an integral
reinforcement surface region, such as an integral reinforcement rib
16a extending along a length dimension L of each tread surface 16,
FIG. 4. The reinforcement ribs 16a have a concave cross-sectional
configuration residing below the plane defined by the tread surface
16. Each tread surface 16 is illustrated as having one
reinforcement rib 16a generally centrally located on the tread
surface. The number and location of integral reinforcement ribs 16a
can be varied as desired in practice of the invention. The integral
reinforcement ribs 16a are formed during the resin spraying molding
operation described above simply by providing the tread-forming
surfaces of the master mold with rib-forming raised
projections.
[0035] The tread surfaces 16 include a plurality of holes 16c that
are adapted to receive fasteners 48 on the tread members. The holes
16c are formed in the tread surfaces 16 by first molding a dimple
and then drilling once stairway 10 is removed from the mold. For
purposes of illustration only, the holes 16c are formed in a
pattern or array shown in FIG. 4 to receive the fasteners 48 of the
tread member 18 as shown in FIGS. 6 and 8.
[0036] The dimensions of the tread surfaces 16 can be selected as
desired for a particular construction application. The tread
surfaces 16 typically are of equal depth dimension DT from one
tread surface to the next. The topmost tread 16 can be cut to have
a shorter depth dimension d to fit an existing building
configuration as illustrated in FIG. 1. The topmost tread 16 if
uncut would extend farther to the right to form a landing at the
top of the stairway of FIG. 1. The riser surface 14 and adjacent
tread surface 16 define an included draft angle A, FIG. 1, that can
be 91 degrees for purposes of illustration but not limitation as
other included angles A can be used.
[0037] The stairway 10 can include an optional landing surface (not
shown) proximate the top and/or bottom of the stairway. For
example, the topmost tread 16 can be extended in a direction to the
right in FIG. 1 to form a landing surface for the top of the
stairway. A preformed landing member similar to a tread member 18
is fastened over the landing surface. Such a landing surface and
landing member are described in copending U.S. application Ser. No.
09/711,854 filed Nov. 13, 2000, the teachings of which are
incorporated herein by reference.
[0038] The stairway can be made by spraying a suitable plastic
material on a master mold. For purposes of illustration, the
stairway 10 can be made by spraying in a first step, a first outer
filled plastic resin layer 45 (FIG. 7) using a filled resin system
#1 as described in Table #1 through a commercially available
two-chamber spray gun (e.g. PRO Series spray gun from manufacturer,
Venus Gusmer Inc.) having a static mixer of sufficient length to
thoroughly mix filled resin system #1 with a methyl ethyl ketone
peroxide catalyst (e.g. High Point 90 by Witco Corporation) as it
is sprayed on the surface of the mold. This mixture (i.e. resin
system #1 and catalyst) is then allowed to polymerize or cure. The
filled resin system #1 (step 1) is sprayed to form outer filled
resin layer 45 to have a nominal thickness of about 0.030 inch.
Although spraying is the preferred method of application, filled
resin system #1 can be hand catalyzed, mixed, and then brushed on
or poured on the surface of the mold and allowed to polymerized or
cure.
[0039] After the aforementioned mixture forming outer filled resin
layer 45 has cured, a step 2 involves spraying a second plastic
layer 47A behind the first layer 45. The second layer 47A is formed
by spraying the resin system #1 as described above on layer 45
immediately followed by spraying filled resin system #2 as
described in Table II and chopped fiberglass fibers through a
two-chamber gun of the type described above having a static mixer
of sufficient length to thoroughly mix filled resin system #2 with
the above catalyst as it is sprayed. This spray gun is also be
equipped with a conventional chopper head available from the above
manufacturer to cut the fiberglass gun roving into 1" lengths. Both
the chopped fibers and the filled resin system #2 are
simultaneously sprayed behind the filled resin system #1 at a
preferred ratio of 70% by weight of resin and 30% by weight of
chopped fiberglass. The mixture is then rolled out and allowed to
polymerize or cure to form fiber reinforced filled resin layer 47A.
Step #2 described above is repeated twice more to form fiber
reinforced filled resin layers 47B and 47C. Each fiber reinforced
filled resin layer 47A, 47B, 47C has a nominal thickness of about
0.060 inch. The total thickness of the wall W of stairway 10 thus
is about 0.21 inch, although other wall thicknesses can used in
practice of the invention. A cross-section through the wall W of
the one-piece base 20 is shown in FIG. 7.
[0040] The joist attachment member 20 is incorporated in the
stairway 10 by placing member 20 on the wall W after the layers
47A, 47B, 47C are cured. The member 20 is then sprayed as described
above to form additional layers 47A, 47B, 47C on the fastening
member 20 to form the channel walls 22a, 22b, 22c in-situ
thereabout and thereby incorporate the fastening member 20 into the
stairway as integral element thereof.
1TABLE 1 Resin System #I Filled resin system #1 comprises a mixture
consisting of 50% by weight of a synthetic plastic resin selected
from the polyester or vinyl ester group, (although other
thermosetting or other plastic resins may be found suitable), 46%
by weight of a wollastonite based product as described in U.S. Pat.
No. #4 568 604 and sold under the trademark "KZ6" by Ceramic
Technologies Corporation of Rowley Iowa, 2% by weight of the
mineral Talc, 1% by weight of a hollow microsphere sold under the
trademark "Dualite" by Pierce and Stevens Corporation of Buffalo
NY, and 1% by weight Titanium Dioxide. It will be understood by
those skilled in the art that the above mixture has been found to
be preferred but that deviation from the percents listed or the
filler or other constituents used is within the scope of this
invention.
[0041]
2TABLE II Resin System #2 Resin system #2 comprises a mixture
consisting of 75% by weight of a synthetic plastic resin selected
from the polyester or vinyl ester group, (although other
thermosetting plastic resins may be found suitable), 21 1/2% by
weight of a wollastonite based product as described in U.S. Pat.
No. #4 568 604 and sold under the trademark "KZ9" by Ceramic
Technologies Corporation of Rowley Iowa, 2% by weight of the
mineral Talc, 1/2% by weight of a hollow microsphere sold under the
trademark "Dualite" by Pierce and Stevens Corporation of Buffalo
NY, and 1% by weight Titanium Dioxide. It will be understood by
those skilled in the art that the above mixture has been found to
be preferred but that deviation from the percents listed or the
filler or other constituents used is within the scope of this
invention.
[0042] It will be noted that the filled resin system #1 and filled
resin system #2 each contain the catalyst described above so that
the layers 45, 47A, 47B, 47C comprising the stairway wall W cure on
the mold without the need for heating to this end.
[0043] The resin system #1 without chopped fibers and resin system
#2 with chopped fiberglass fibers as described above are sprayed on
a one piece, open-bottom master mold (not shown). The master mold
is fabricated of the same material layers as described above
sprayed on a master wooden pattern having a shape corresponding to
that of the stairway 10. The fabricated master mold is provided
with a draft angle of 9 degrees (or other suitable draft angle)
that is imparted to the stairway 10 as a 9 degree top-to-bottom
draft angle on each of the stringers 12 and risers 14. This draft
angle allows the sprayed, cured stairway 10 to be removed
vertically from the mold out of the open bottom of the mold, the
stairway 10 being sprayed with the tread surfaces 16 oriented to
face downwardly.
[0044] The preformed tread members 18 and the landing member (not
shown), if used, typically are molded by applying (e.g. spraying,
brushing and the like) a product sold under the trademark "KZ
Ceramic Gelcoat", and taught in U.S. Pat. No. 5,688,851, herein
called "KZ Gelcoat", mixed with the above catalyst to the surface
of a face-mold of a two-part mold and allowed to polymerize or cure
to provide a layer nominal thickness of about 0.030 inch. Then,
multiple layers (usually 2 to 4) of continuous fiberglass mat M,
FIG. 6, are placed in the face-mold behind the cured "KZ Gelcoat",
the mold is then closed by clamping, bolting or otherwise
connecting a rear-mold to the face-mold and filled with the above
filled resin system #2 mixed with the above catalyst and allowed to
polymerize or cure. The thickness of each tread member 18 and
landing member, if used, is nominally about 0.20 inch.
[0045] The tread members 18 and landing member can be individually
molded in a conventional two-part cavity mold comprising a
face-mold and rear-mold mate-able to form a closed cavity, such as
is used in RTM (Resin Transfer Molding) or compression molding.
Other molding techniques, which can be used, include but are not
limited to injection molding, low pressure composite molding, and
other conventional molding processes.
[0046] The tread members 18 and landing member, if used, are molded
to capture integrally therein a plurality of threaded fasteners 48
each having enlarged fastener head 48a and a threaded shank 48b,
FIG. 6. The fasteners 48 are captured in each tread member by
placing the head of the fastener between the aforementioned layers
of the fiberglass mats M before molding. Capturing of the fasteners
48 in this manner is advantageous to hide the fasteners from view
when the stairway 10 is assembled.
[0047] The tread members 18 and the landing member, if used, are
molded to include integral pilot protrusions 18p on the underside
thereof and adapted to be received in a respective hole 16c in the
underlying tread surface 16 and landing surface.
[0048] The tread members 18 are also molded to include an integral
bull nose 18n that depends or extends downwardly about the front
periphery of the tread member to overlap and hide the adjacent
riser surface 14 located therebelow as will be appreciated from
FIG. 8. The rear periphery of each tread member 18 comprises a
straight edge 18e. The bull nose 18n includes a straight lip region
18nl and a radius region 18nr.
[0049] The landing member, if used, is also molded to include an
integral bull nose that depends or extends downwardly about the
front periphery of the landing member to overlap and hide the
adjacent riser surface 14 located therebelow.
[0050] The bull noses 18n on the tread members 18 and landing
member, if used, provide an aesthetically pleasing appearance to
the stairway when assembled.
[0051] The tread members 18 and landing member can be made of
materials other than plastic material described above. For example,
the invention envisions making the tread members 18 and landing
member, if used, out of wood, metal, and other suitable materials
using conventional wood working, metal working and other
techniques.
[0052] The tread members 18 are fastened to the respective tread
surfaces 16 by inserting the threaded shank 48b of the fasteners 48
through the holes 16c and assembling and tightening a nut 52 on the
shank 48b with a washer 53 positioned between the nut 52 and the
underside of the tread member, FIG. 6. The landing member, if used,
can be fastened in like manner to a landing surface provided on the
stairway 10.
[0053] The tread members 18 and the landing member, if used, can be
molded to provide an anti-slip surface on the upper surface
thereof. A diamond anti-slip surface pattern for purposes of
illustration only can be molded into the entire upper surface of
the tread members 18 and landing member, if used, if desired as
described in U.S. Ser. No. 09/711,854 filed Nov. 13, 2000,
incorporated herein by reference. Other anti-slip surfaces can be
molded into the upper surfaces of the tread members and/or the
landing member to suit a particular construction application.
Moreover, the tread members 18 and landing member, if used, can be
molded to impart any desired decorative appearance thereto. For
example, they can be molded to have a stone, brick or other desired
surface appearance. Still further, the color of the tread members
and the landing member can be selected to provide any desired
aesthetic appearance. For example, the color of the tread members
18 and landing member can be different from that of the stairway 10
and matched to the color of the building or structure.
[0054] In use, should a tread member 18 or a landing member, if
used, become damaged for some reason, it can be removed from the
stairway 10 by removing the nuts 52 and washer 53 and then
fastening a replacement tread member or landing member in its
place.
[0055] The stairway 10 can be installed in a stairwell formed by
wall studs WS in conventional manner as shown in FIG. 9. The upper
end of the stairway 10 can be fastened to the floor joist J as
shown in FIG. 1 and described above. The upper region of the
stringers 12 also can be fastened to the wall studs WS by screws 34
extending through wall 12c of each stringer 12 into the wall studs.
The lower end of the stairway 10 can be fastened to wall studs WS
located proximate stringers 12 using like screws 34 extending
through walls 12c of each stringer 12. A filler strip or shim lathe
60 is nailed on the wall studs WS to be flush with the wall 12c of
each stringer 12 as shown. Sheet rock (also known as dry wall
sheet) 62 is then nailed on the filler strip or shim lathe 60 to
overlap the stringer wall 12c as shown in FIG. 9. A bead of caulk
64 then can be applied to complete the joint between the stairway
10 and the sheet rock 62. A handrail 70 mounted on bracket 72 is
fastened to the wall studs WS using screws 72 extending through the
bracket 72 into the wall studs as shown. The handrail can extend
the length of the stringers 12.
[0056] Referring to FIGS. 10-13, a free-standing stairway 10'
pursuant to another embodiment of the invention is illustrated. In
FIGS. 10-13, like features of FIGS. 1-9 are represented by like
reference numerals primed.
[0057] The stairway 10' includes stringers 12' that each include
upstanding inner wall 12a', a lateral wall 12b', and a downwardly
extending outermost wall 12d', with the walls 12b' being molded to
include receptacles 13a' and 13b' for receiving the lower ends of
ballaster posts 80' and newel posts 82', respectively, that support
a handrail 84'. The outermost wall 12d' extends downwardly to
provide the outer visible wall of the stairway. Although not shown
in FIGS. 10-13, reinforcing gussets similar to gussets 15 of FIGS.
1-9 are provided on stairway 101. The receptacles 13a' are sized
and shaped to receive the lower ends of the ballaster posts 80',
while the receptacles 13b' are sized and shaped to receive the
lower ends of the newel posts 82' as shown in FIG. 12. The lower
ends of the posts 80' and 82' are fastened in the receptacle 13a',
13b' by suitable adhesive and/or by a screw (not shown) extending
upwardly through a hole 17' drilled in the bottom of each
receptacle 13a', 13b' (only some of the holes 17' being shown for
the receptacles 13b'). The ballaster posts, newel posts and
handrail can be made of wood, metal (e.g. wrought iron), plastic
material and other materials.
[0058] The upper region of the stairway 10' can be fastened to the
upper floor 30' via its floor or landing joist J'. The lower region
of the stairway 10' can rest on the lower floor 35' and be fastened
to the floor by a screw (not shown) extending through the bottom of
each ballaster receptacle 13a' for fastening to the floor or
landing 35', which can be wood, concrete or other floor
conventional floor material. The type of screw used to fasten the
stairway on the floor or landing 35' would be selected in
dependence on the floor or landing material present. If the
ballaster posts are glued in the receptacles 13a', the floor screw
can extend through hole 17'. An additional screw hole (not shown)
can be provided otherwise in the bottom of receptacle 13a'.
[0059] A decorative cover panel 100' can be attached by screws 102'
to lowermost (bottom) edges of stringer outer walls 12d' to hide
the bottom of the stairway from view, FIGS. 10 and 13. The channel
22' may include chamfered corner 22e' to accommodate the cover
panel 100' as illustrated in FIG. 10. The cover panel 100' can be
made of sheet rock (drywall), wood or composite wood paneling,
plastic paneling material or any other panel material.
[0060] Although not shown in FIGS. 10-13, it is understood that the
tread surfaces 16' of stairway 10' will have fastened thereon as
described above a respective tread member like tread member 18 of
FIG. 8 to complete the stairway 10'.
[0061] Referring to FIGS. 14-16 where like features of previous
figures are represented by like reference numerals double primed,
an embodiment of the invention envisions fastening one or more of
the tread members 18", on a tread T" of one or more steps S" of an
existing stairway SW" made of wood (FIG. 14), concrete (FIG. 15),
metal (e.g. steel, FIG. 16) and other materials. One or more tread
members 18" can be fastened to refurbish one or more worn or
damaged treads of the stairway between the stringers ST'.
Alternately, one or more safety-colored (e.g. yellow, orange, red,
etc,) thread members 18" having a color different from the color of
the steps S" can be fastened to one or more steps S" to enhance the
visual appearance of the step(s) for aesthetic and/or safety
purposes. The tread members 18' can be fastened to the treads T" by
any appropriate means such as threaded fasteners 48", nuts 52", and
washers 53" as illustrated in FIGS. 14-16, adhesive, and/or other
suitable fastening technique. The tread members 18" can be molded
or post-mold drilled as described above to include holes 18c" to
receive the fasteners 48', rather than having the fasteners
captured integrally in the tread member 18". The treads T" can be
conventionally drilled to provide holes H" to receive the fasteners
48". Alternately, if the thread members 18" will be adhesively
attached to the steps S", the holes 18c" may be omitted. Each tread
member 18" can include the bull nose 18n" that overlaps the
adjacent riser surface of the step S" and a straight edge 18e" at
the rear of the tread member 18". The tread members 18" can be
molded without or with the pilot protrusions 18p, FIG. 6, described
above. Otherwise, the tread members 18" have a cross-section
similar to that of FIG. 6. In FIGS. 14-16, the pilot protrusions
are omitted from the tread members 18".
[0062] FIG. 15 illustrates a landing member 19" to be fastened on
the top landing surface L" of the concrete stairway SW". The
landing member 19" is molded or drilled to include holes 19c" in
the same manner described above for the tread members 18 and can be
fastened on the stairway landing surface L' using fasteners 48"
through holes 19c", nuts 52" and washer 53" as described for the
tread members 18", adhesive or any other suitable fastening
technique as described for the tread members 18". The landing
member 19" includes a bull nose 19n" around its entire
periphery.
[0063] The present invention is advantageous to provide an improved
prefabricated stairway for use between floors of a building or
other structure where the stairway is relatively lightweight to
facilitate transport to and proper positioning at the building or
structure site and yet sturdy enough to withstand loads encountered
in use, is resistant to wear and chemicals, and offers improved
stairway aesthetics. Also, the invention envisions fastening one or
more tread members on worn steps to refurbish the steps and/or to
enhance the visual appearance of the step(s) for aesthetic or
safety purposes.
[0064] Although the invention has been described with respect to
certain specific embodiments, it is not limited thereto and can be
modified and changed within the scope of the appended claims.
* * * * *