U.S. patent application number 11/714774 was filed with the patent office on 2008-09-11 for stair system.
Invention is credited to Koo Dong Chung, Yong Hwan Won.
Application Number | 20080216422 11/714774 |
Document ID | / |
Family ID | 39740232 |
Filed Date | 2008-09-11 |
United States Patent
Application |
20080216422 |
Kind Code |
A1 |
Chung; Koo Dong ; et
al. |
September 11, 2008 |
Stair system
Abstract
A stair system including an upper tread having a substantially
planar body portion, a stair nose portion located at one side of
the planar body portion, and a dado located behind the stair nose
portion, at least one lower tread, the lower tread having a
substantially planar body portion, a stair nose portion located at
one side of the planar body portion, a dado located behind the
stair nose portion, and a groove located at a side opposite the
stair nose portion, and at least two risers, each riser having a
substantially planar body portion. In the stair system, one of the
at least two risers is receivable between the dado of the upper
tread and the groove of the lower tread and the other of the at
least two risers is receivable in the dado of the lower tread.
Methods for assembling a stair system are also provided.
Inventors: |
Chung; Koo Dong; (Lorton,
VA) ; Won; Yong Hwan; (Waldorf, MD) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Family ID: |
39740232 |
Appl. No.: |
11/714774 |
Filed: |
March 7, 2007 |
Current U.S.
Class: |
52/188 |
Current CPC
Class: |
E04F 11/16 20130101;
E04F 11/02 20130101; E04F 11/108 20130101 |
Class at
Publication: |
52/188 |
International
Class: |
E04F 11/00 20060101
E04F011/00 |
Claims
1. A stair system comprising: an upper tread having a substantially
planar body portion, a stair nose portion located at one side of
the planar body portion, and a dado located behind the stair nose
portion; at least one lower tread, the lower tread having a
substantially planar body portion, a stair nose portion located at
one side of the planar body portion, a dado located behind the
stair nose portion, and a groove located at a side opposite the
stair nose portion; and at least two risers, each riser having a
substantially planar body portion, one of the at least two risers
being receivable between the dado of the upper tread and the groove
of the lower tread, the other of the at least two risers being
receivable in the dado of the lower tread.
2. The stair system according to claim 1, wherein the groove of the
at least one lower tread is formed in an upper surface of the
planar body portion.
3. The stair system according to claim 2, wherein the groove of the
at least one lower tread is a rabbet.
4. The stair system according to claim 2, wherein the groove of the
at least one lower tread is a dado.
5. The stair system according to claim 1, wherein the at least one
lower tread includes a plurality of lower treads, each of the lower
tread having a substantially planar body portion, a stair nose
portion located at one side of the planar body portion, a dado
located behind the stair nose portion, and a groove located at a
side opposite the stair nose portion; and wherein the at least two
risers includes a plurality of risers such that the number of
risers corresponds to the number of lower treads plus the upper
riser.
6. The stair system according to claim 1, wherein the stair nose
portions of the upper tread has a thickness substantially equal to
the thickness of the planar body portion of the upper tread and the
stair nose portion of the at least one lower tread has a thickness
substantially equal to the thickness of the planar body portion of
the at least one lower tread.
7. The stair system according to claim 1, wherein the stair nose
portions of the upper tread has a thickness greater tan the
thickness of the planar body portion of the upper tread and the
stair nose portion of the at least one lower tread has a thickness
greater than the thickness of the planar body portion of the at
least one lower tread.
8. The stair system according to claim 1, further comprising: at
least two stringers, each stringer having a plurality of tread
sides and a plurality of riser sides; a plurality of tread
sub-floorings corresponding to the plurality of tread sides, each
of the plurality of tread sub-floorings spanning between the at
least two stringers and affixed to corresponding tread sides; a
plurality of riser sub-floorings corresponding to the plurality of
riser sides, each of the plurality of riser sub-floorings spanning
between the at least two stringers and affixed to corresponding
riser sides.
9. The stair system according to claim 8, wherein the upper tread
is affixed to one of the plurality of tread sub-floorings, the at
least one lower tread is affixed to another of the plurality of
tread sub-floorings, and each of the at least two risers are
affixed to different riser sub-floorings.
10. The stair system according to claim 8, wherein an end of each
of the tread sub-flooring extends beyond the lower adjacent riser
sub-flooring such that the riser sub-flooring is recessed behind
the end of the tread sub-flooring.
11. The stair system according to claim 10, wherein the upper tread
is affixed to one of the plurality of tread sub-floorings and the
at least one lower tread is affixed to another of the plurality of
tread sub-floorings.
12. The stair system according to claim 11, wherein each of the
plurality of risers are affixed to the corresponding dado.
13. The stair system according to claim 12, wherein each of the
plurality of risers are affixed to the end of the upper adjacent
tread sub-flooring.
14. A method for assembling a stair system, the stair system having
at least two stringers, each stringer having a plurality of tread
sides and a plurality of riser sides, a plurality of tread
sub-floorings corresponding to the plurality of tread sides, each
of the plurality of tread sub-floorings spanning between the at
least two stringers and affixed to corresponding tread sides, and a
plurality of riser sub-floorings corresponding to the plurality of
riser sides, each of the plurality of riser sub-floorings spanning
between the at least two stringers and affixed to corresponding
riser sides, the method comprising: affixing a first riser to the
lowermost riser sub-flooring of the plurality of riser
sub-floorings; affixing a lower tread to one of the plurality of
tread sub-floorings adjacent the lowermost riser sub-flooring, the
lower tread having a substantially planar body portion, a stair
nose portion located at one side of the planar body portion, a dado
located behind the stair nose portion, and a groove located at a
side opposite the stair nose portion, the first riser being
received in the dado of the lower tread; affixing a second riser to
the uppermost riser sub-flooring of the plurality of riser
sub-floorings, the second riser being received in the groove of the
lower tread; and affixing an upper tread to one of the plurality of
tread sub-floorings adjacent the uppermost riser sub-flooring, the
upper tread having a substantially planar body portion, a stair
nose portion located at one side of the planar body portion, and a
dado located behind the stair nose portion, the second riser being
received between the groove of the lower tread and the dado of the
upper tread.
15. The method according to claim 14, further comprising: affixing
an intermediate riser to one of the riser sub-floorings located
between the lowermost riser sub-flooring and the uppermost riser
sub-flooring; and affixing an intermediate tread to one of the
tread sub-floorings located between the lowermost tread
sub-flooring and the uppermost tread sub-flooring, the intermediate
tread having a substantially planar body portion, a stair nose
portion located at one side of the planar body portion, a dado
located behind the stair nose portion, and a groove located at a
side opposite the stair nose portion.
16. The method according to claim 15, wherein there is only three
risers, the intermediate riser is received in the groove of the
lower tread and the dado of the intermediate tread and the second
riser is received in the groove of the intermediate tread and the
dado of the upper tread.
17. A method for assembling a stair system, the stair system having
at least two stringers, each stringer having a plurality of tread
sides and a plurality of riser sides, a plurality of tread
sub-floorings corresponding to the plurality of tread sides, an end
of each of the tread sub-flooring extends beyond the lower adjacent
riser sub-flooring such that the riser sub-flooring is recessed
behind the end of the tread sub-flooring, each of the plurality of
tread sub-floorings spanning between the at least two stringers and
affixed to corresponding tread sides, and a plurality of riser
sub-floorings corresponding to the plurality of riser sides, each
of the plurality of riser sub-floorings spanning between the at
least two stringers and affixed to corresponding riser sides, the
method comprising: affixing a first riser to the lowermost tread
sub-flooring of the plurality of tread sub-floorings; affixing a
lower tread to the lowermost tread sub-flooring of the plurality of
tread sub-floorings adjacent the lowermost riser sub-flooring, the
lower tread having a substantially planar body portion, a stair
nose portion located at one side of the planar body portion, a dado
located behind the stair nose portion, and a groove located at a
side opposite the stair nose portion, the first riser being
received in the dado of the lower tread; affixing a second riser to
the uppermost tread sub-flooring of the plurality of tread
sub-floorings; and affixing an upper tread to the uppermost tread
sub-flooring of the plurality of tread sub-floorings adjacent the
uppermost riser sub-flooring, the upper tread having a
substantially planar body portion, a stair nose portion located at
one side of the planar body portion, and a dado located behind the
stair nose portion, the second riser being received in the dado of
the upper tread.
18. The method according to claim 17, further comprising: affixing
an intermediate riser to one of the tread sub-floorings located
between the lowermost tread sub-flooring and the uppermost riser
sub-flooring; and affixing an intermediate tread to one of the
tread sub-floorings located between the lowermost tread
sub-flooring and the uppermost tread sub-flooring, the intermediate
tread having a substantially planar body portion, a stair nose
portion located at one side of the planar body portion, a dado
located behind the stair nose portion, and a groove located at a
side opposite the stair nose portion.
19. The method according to claim 18, wherein there is only three
risers, the intermediate riser is received in the groove of the
lower tread and the dado of the intermediate tread and the second
riser is received in the groove of the intermediate tread and the
dado of the upper tread.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is generally directed to a stair
system, and more particularly to modular treads and risers of a
stair system.
[0003] 2. Description of Related Art
[0004] Generally, stair systems having nose moldings have been
constructed in a similar manner using the same basic methods. For
example, most stair systems employ a plurality of stringers having
tread sides cut out, on which are secured tread sub flooring that
span between the stringers. The stringers also have riser sides cut
out, on which are secured riser sub floorings that also span
between the stringers. Depending on the finishing materials for the
stair system, a tread and riser may be mounted to the tread sub
flooring or carpeting with or without padding may be affixed to the
tread sub flooring and riser sub flooring. Where carpeting is used,
the tread sub flooring may provide an overhang to allow the carpet
to be affixed to the underside of the overhang, thereby hiding the
means of fastening the carpet to the tread sub flooring. Sub
flooring is normally secured using nails, screws, and/or
adhesives
[0005] Because most stair systems are normally built from the top
down, in the case of steps having a wood finish, the top most tread
is attached using adhesive and a stair nose is attached to the end
of the tread to overlap a portion of the tread and to cover the
remainder of the tread sub flooring. Generally the stair nose
extends beyond the tread sub flooring a sufficient distance to
allow a riser to be disposed beneath the stair nose.
[0006] The first step below the top step is assembled by placing a
riser underneath the stair nose and affixing it to the riser sub
flooring using either fasteners or adhesive. The next tread must be
cut to have a square edge, as it must abut the riser. Then the
stair nose is attached to the end of the tread to overlap a portion
of the tread and to cover the remainder of the tread sub flooring
as discussed above. This process is repeated for each successive
step.
[0007] In an alternative stair system, the stair nose may be
affixed to the tread by using a tongue and groove relationship. The
tread and risers are affixed to the tread sub flooring and riser
sub flooring using fasteners or adhesive as described above.
[0008] In all of the above cases, it is important that expansion of
the wood be accounted for in the assembly of the stairs. As such,
sufficient gaps must be provided between pieces of wood to allow
the individual pieces to expand.
[0009] The first system permits the tread and risers to be
free-floating, allow them to contract and expand with changes in
temperature and humidity. However, they are unattractive in that
the stair nose is higher than the tread because of the overlapping
arrangement.
[0010] The second system does allow the tread and stair nose to be
coplanar, but because they are joined by the tongue and groove, the
system does not allow the tread and risers to be free-floating.
[0011] U.S. Pat. No. 6,115,975 proposes a solution to providing a
nose stair that is coplanar with the tread, but still allows the
tread and riser to be free floating. The stair system provides a
stair nose connected by a tongue and groove arrangement to a tread.
A back molding is affixed to the tread and includes a groove to
receive a riser therein. A corresponding groove is formed in the
stair nose such that the riser is held between the stair nose and
the back molding. In this manner, the riser can be allowed to
expand and contract with the temperature and humidity, thereby
providing treads and risers that are free floating.
[0012] While the solution proposed in U.S. Pat. No. 6,115,975
address the problems identified above, it is a complicated system
that requires many additional components. As a result the assembly
process is unnecessarily complicated.
BRIEF SUMMARY OF THE INVENTION
[0013] According to principles of this invention, a stair system is
provided that minimizes the components of the stair system and
provides an efficient assembly process. The stair system includes
an upper tread having a substantially planar body portion, a stair
nose portion located at one side of the planar body portion, and a
dado located behind the stair nose portion, at least one lower
tread, the lower tread having a substantially planar body portion,
a stair nose portion located at one side of the planar body
portion, a dado located behind the stair nose portion, and a groove
located at a side opposite the stair nose portion, and at least two
risers, each riser having a substantially planar body portion. In
the stair system, one of the at least two risers is receivable
between the dado of the upper tread and the groove of the lower
tread and the other of the at least two risers is receivable in the
dado of the lower tread.
[0014] In another aspect, the groove of the at least one lower
tread may be formed in an upper surface of the planar body portion.
The groove of the at least one lower tread may be a rabbet or a
dado.
[0015] In a different aspect, the at least one lower tread includes
a plurality of lower treads. Each of the lower tread may have a
substantially planar body portion, a stair nose portion located at
one side of the planar body portion, a dado located behind the
stair nose portion, and a groove located at a side opposite the
stair nose portion. In addition, the at least two risers may
include a plurality of risers such that the number of risers
corresponds to the number of lower treads plus the upper riser.
[0016] In yet another aspect, the stair nose portions of the upper
tread may have a thickness substantially equal to the thickness of
the planar body portion of the upper tread and the stair nose
portion of the at least one lower tread may have a thickness
substantially equal to the thickness of the planar body portion of
the at least one lower tread. Alternatively, the stair nose
portions of the upper tread may have a thickness greater than the
thickness of the planar body portion of the upper tread and the
stair nose portion of the at least one lower tread may have a
thickness greater than the thickness of the planar body portion of
the at least one lower tread.
[0017] In a further aspect, the stair system includes at least two
stringers, each stringer having a plurality of tread sides and a
plurality of riser sides, a plurality of tread sub-floorings
corresponding to the plurality of tread sides, each of the
plurality of tread sub-floorings spanning between the at least two
stringers and affixed to corresponding tread sides, and a plurality
of riser sub-floorings corresponding to the plurality of riser
sides, each of the plurality of riser sub-floorings spanning
between the at least two stringers and affixed to corresponding
riser sides.
[0018] In still another aspect, the upper tread may be affixed to
one of the plurality of tread sub-floorings, the at least one lower
tread may be affixed to another of the plurality of tread
sub-floorings, and each of the at least two risers may be affixed
to different riser sub-floorings.
[0019] In yet another aspect, an end of each of the tread
sub-flooring may extend beyond the lower adjacent riser
sub-flooring such that the riser sub-flooring is recessed behind
the end of the tread sub-flooring.
[0020] In a further aspect, the upper tread may be affixed to one
of the plurality of tread sub-floorings and the at least one lower
tread is affixed to another of the plurality of tread
sub-floorings.
[0021] In still a further aspect, each of the plurality of risers
may be affixed to the corresponding dado. Alternatively, each of
the plurality of risers may be affixed to the end of the upper
adjacent tread sub-flooring.
[0022] In accordance with another aspect of the present invention,
a method for assembling a stair system, the stair system having at
least two stringers, each stringer having a plurality of tread
sides and a plurality of riser sides, a plurality of tread
sub-floorings corresponding to the plurality of tread sides, each
of the plurality of tread sub-floorings spanning between the at
least two stringers and affixed to corresponding tread sides, and a
plurality of riser sub-floorings corresponding to the plurality of
riser sides, each of the plurality of riser sub-floorings spanning
between the at least two stringers and affixed to corresponding
riser sides. The method includes affixing a first riser to the
lowermost riser sub-flooring of the plurality of riser
sub-floorings, affixing a lower tread to one of the plurality of
tread sub-floorings adjacent the lowermost riser sub-flooring, the
lower tread having a substantially planar body portion, a stair
nose portion located at one side of the planar body portion, a dado
located behind the stair nose portion, and a groove located at a
side opposite the stair nose portion, the first riser being
receivable in the dado of the lower tread, affixing a second riser
to the uppermost riser sub-flooring of the plurality of riser
sub-floorings, the second riser being received in the groove of the
lower tread, and affixing an upper tread to one of the plurality of
tread sub-floorings adjacent the uppermost riser sub-flooring, the
upper tread having a substantially planar body portion, a stair
nose portion located at one side of the planar body portion, and a
dado located behind the stair nose portion, the second riser being
received between the groove of the lower tread and the dado of the
upper tread.
[0023] In another aspect, the method may include affixing an
intermediate riser to one of the riser sub-floorings located
between the lowermost riser sub-flooring and the uppermost riser
sub-flooring, and affixing an intermediate tread to one of the
tread sub-floorings located between the lowermost tread
sub-flooring and the uppermost tread sub-flooring, the intermediate
tread having a substantially planar body portion, a stair nose
portion located at one side of the planar body portion, a dado
located behind the stair nose portion, and a groove located at a
side opposite the stair nose portion.
[0024] In a further aspect, where there is only three risers, the
intermediate riser is received in the groove of the lower tread and
the dado of the intermediate tread and the second riser is received
in the groove of the intermediate tread and the dado of the upper
tread.
[0025] In still another aspect of present invention, another method
for assembling a stair system is provided, where the stair system
has at least two stringers, each stringer having a plurality of
tread sides and a plurality of riser sides, a plurality of tread
sub-floorings corresponding to the plurality of tread sides, an end
of each of the tread sub-flooring extends beyond the lower adjacent
riser sub-flooring such that the riser sub-flooring is recessed
behind the end of the tread sub-flooring, each of the plurality of
tread sub-floorings spanning between the at least two stringers and
affixed to corresponding tread sides, and a plurality of riser
sub-floorings corresponding to the plurality of riser sides, each
of the plurality of riser sub-floorings spanning between the at
least two stringers and affixed to corresponding riser sides. The
method includes affixing a first riser to the lowermost tread
sub-flooring of the plurality of tread sub-floorings, affixing a
lower tread to the lowermost tread sub-flooring of the plurality of
tread sub-floorings adjacent the lowermost riser sub-flooring, the
lower tread having a substantially planar body portion, a stair
nose portion located at one side of the planar body portion, a dado
located behind the stair nose portion, and a groove located at a
side opposite the stair nose portion, the first riser being
received in the dado of the lower tread, affixing a second riser to
the uppermost tread sub-flooring of the plurality of tread
sub-floorings, and affixing an upper tread to the uppermost tread
sub-flooring of the plurality of tread sub-floorings adjacent the
uppermost riser sub-flooring, the upper tread having a
substantially planar body portion, a stair nose portion located at
one side of the planar body portion, and a dado located behind the
stair nose portion, the second riser being received in the dado of
the upper tread.
[0026] In another aspect, the method includes affixing an
intermediate riser to one of the tread sub-floorings located
between the lowermost tread sub-flooring and the uppermost riser
sub-flooring, and affixing an intermediate tread to one of the
tread sub-floorings located between the lowermost tread
sub-flooring and the uppermost tread sub-flooring, the intermediate
tread having a substantially planar body portion, a stair nose
portion located at one side of the planar body portion, a dado
located behind the stair nose portion, and a groove located at a
side opposite the stair nose portion.
[0027] In a further aspect, where there is only three risers, the
intermediate riser is received in the groove of the lower tread and
the dado of the intermediate tread and the second riser is received
in the groove of the intermediate tread and the dado of the upper
tread.
[0028] Further scope of applicability of the present application
will become more apparent from the detailed description given
hereinafter. However, it should be understood that the detailed
description and specific examples, while indicating preferred
embodiments of the invention, are given by way of illustration
only, since various changes and modifications within the spirit and
scope of the invention will become apparent to those skilled in the
art from the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The present invention will become more fully understood from
the detailed description given hereinbelow and the accompanying
drawings which are given by way of illustration only, and thus are
not limitative of the present invention and wherein:
[0030] FIG. 1 is a partially exploded perspective view of the stair
system according to a first exemplary embodiment; and
[0031] FIG. 2 is a partially exploded perspective view of the stair
system according to a second exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring to FIG. 1, the stair system 100 according to the
first exemplary embodiment includes conventional stringers 110 (one
shown), each stringer 110 provides a plurality of tread sides 112
and a plurality of riser sides 114 formed therein. A tread sub
flooring 116 spans between corresponding tread sides 112 and a
riser sub flooring 118 spans between corresponding riser side 114.
The stringers 110, tread sub floorings 116, and riser sub floorings
118 are assembled using conventional techniques including fasteners
and/or adhesives.
[0033] The stair system 100 includes at least two different treads
depending on the location of the tread. As seen in FIG. 1, the
uppermost tread or top tread 120 has a planar body portion 122 and
a stair nose portion 124. A dado 126 is provided behind the stair
nose portion 124 and extends along the length of the planar body
portion 122. As shown in FIG. 1, the stair nose portion 124 may
have a thickness equal to the planar body portion 122, although it
is understood that the stair nose portion 124 may have a greater
thickness than the planar body portion 122.
[0034] The stair system 100 includes one or more lower treads 130.
Each lower tread 130 has a planar body portion 132 and a stair nose
portion 134. A dado 136 is provided behind the stair nose portion
134 and extends along the length of the planar body portion 132. A
rabbet 138 is provided at the edge opposite the stair nose portion
134 and extends along the length of the planar body portion 132.
Preferably, the width of the rabbet 138 corresponds to the width of
either dado 126, 136 depending on the type of tread, either the
upper or lower tread 120, 130, arranged above it. As shown in FIG.
1, the stair nose portion 134 may have a greater thickness than the
planar body portion 132, although it is understood that the stair
nose portion 134 may have the same thickness as the planar body
portion 132. Preferably, the stair nose portion 134 of the lower
tread 130 has the same thickness of the stair nose portion 124 of
the upper tread 120.
[0035] In addition to the two types of treads discussed above, the
stair system 100 includes at least two risers 140. Each riser 140
has a substantially planar body 142 and is configured to cooperate
with one or more of the treads to form the stair system 100.
[0036] The treads 120, 130 and risers 140 can be made out of
natural plank wood, such as oak plank. However, the treads 120,
130, and risers 140 can be made out of composites or other
preformed materials. In addition, the treads 120, 130, and risers
140 can be provided in many conventional plank widths and
thickness, such as, three-quarter inch or one inch thick, as well
as custom sizes. Preferably, the treads 120, 130 are sized such
that the planar body portion is sufficiently sized to cover the
tread sub flooring and that the rabbets and dados correspond to the
thickness of the risers. In addition, it is desirable that the
depth of the dados and rabbets are selected such that the risers
are free to expand within the corresponding dado and/or rabbet
without applying a large expansion force to the corresponding
treads.
[0037] Next, an exemplary method of assembling the stair system 100
will be described. After the stringers 110, tread sub floorings
116, and riser sub floorings 118 are assembled using conventional
techniques including fasteners and/or adhesives, the rest of the
stair system is attached. Generally, this process begins at the
bottom of the stair system 100 and progresses up the stair system,
although it is understood that a top-down approach may also be
used.
[0038] First, one of the plurality of risers 140 is affixed to the
surface of the riser sub flooring 118 using adhesive. Because this
riser 140 is located at the bottom of the stair system 100, it is
preferably to only use an adhesive. However, it is understood that
fasteners can be used and that if the fasteners are counter-sunk,
then the holes may be filled in to hide their location.
Alternatively, depending on the flooring that the stair system 100
rests on, that the flooring and/or the stair nose portion 134 may
hide fasteners.
[0039] As seen in FIG. 1, the riser 140 extends above the
corresponding tread sub flooring 116 such that the lower tread 130
can be fitted over the riser 140 and that the dado 136 receives the
riser 140 therein. The lower tread 130 can be affixed to the tread
sub flooring 116 using fasteners and/or adhesives. Preferably, the
planar body portion 132 is affixed with adhesive while the fasters
(not shown) extend through the rabbet 138 into the tread sub
flooring 116. In this manner, the lower tread 130 can reliably be
mounted to the tread sub flooring 116, while allowing the fasteners
to be hidden from view by the riser 140 inserted at the back of the
lower tread 130.
[0040] Specifically, the next riser 140 is attached to riser sub
flooring 118 adjacent the rabbet 138. The riser 140 can be attached
to the rabbet 13 8 and/or the riser sub flooring 118 using
adhesive. As noted previously, the riser 140 may also be attached
using fasteners that are counter sunk and filled in and/or the
fasteners may be hidden behind the stair nose portion 134. This
process is repeated with the remaining lower treads 130 until the
top of the stair system 100 is reached.
[0041] As seen in FIG. 1, the upper most riser 140 extends above
the corresponding tread sub flooring 116 such that the upper tread
120 can be fitted over the riser 140 and that the dado 126 receives
the riser 140 therein. The upper tread 120 can be affixed to the
tread sub flooring 116 using fasteners and/or adhesives. Because no
rabbet is provided in the upper tread 120, a continuous planar
finish is achieved.
[0042] Depending on the materials selected, the above-described
stair system 100 can be provided as a free standing stair system
(i.e., no walls provided at either side of the stair system),
supported by one wall, or supported by wall on both sides of the
stair system. Specifically, depending on the finishing of the wood,
the stair system can have an aesthetic appearance without further
finishing.
[0043] Because there are times when it is desirable to remove and
replace existing tread and/or carpeting, the stair system 100 can
be readily adapted to such a process. For example, as seen in FIG.
2, a stair system 200 similar to stair system 100 can be provided.
In this arrangement, existing stringers 210 (one shown) may be
used. Each stringer 210 includes a plurality of tread sides 212 and
a plurality of riser sides 214 formed therein. Existing tread sub
flooring 216 spans between corresponding tread sides 212 and
existing riser sub flooring 218 spans between corresponding riser
side 214. In this exemplary embodiment, the tread sub flooring 216
extends beyond the riser sub flooring a predetermined distance to
allow carpeting to wrap around the edge of the tread sub flooring
216 and to be affixed to a lower surface of the tread sub flooring
216. The stringers 210, tread sub floorings 216, and riser sub
floorings 218 were previously assembled using conventional
techniques including fasteners and/or adhesives.
[0044] As described above for stair system 100, the stair system
200 includes at least two different treads depending on the
location of the tread. As seen in FIG. 2, the uppermost tread or
top tread 220 has a planar body portion 222 and a stair nose
portion 224. A dado 226 is provided behind the stair nose portion
224 and extends along the length of the planar body portion 222. As
shown in FIG. 2, the stair nose portion 224 may have a greater
thickness than the planar body portion 222, although it is
understood that the stair nose portion 224 may have the same
thickness as the planar body portion 222.
[0045] The stair system 200 includes one or more lower treads 230.
Each lower tread 230 has a planar body portion 232 and a stair nose
portion 234. A dado 236 is provided behind the stair nose portion
234 and extends along the length of the planar body portion 232. A
second dado 238 is provided near the edge opposite the stair nose
portion 234 and extends along the length of the planar body portion
232. Preferably, the width of the second dado 238 corresponds to
the width of either dado 226, 236 depending on the type of tread,
either the upper or lower tread 220, 230, arranged above it. As
shown in FIG. 2, the stair nose portion 234 may have a greater
thickness than the planar body portion 232, although it is
understood that the stair nose portion 234 may have the same
thickness as the planar body portion 232. Preferably, the stair
nose portion 234 of the lower tread 230 has the same thickness of
the stair nose portion 224 of the upper tread 220.
[0046] In addition to the two types of treads discussed above, the
stair system 200 includes at least two risers 240. Each riser 240
has a substantially planar body 242 and is configured to cooperate
with one or more of the treads to form the stair system 200.
[0047] The treads 220, 230 and risers 240 can be made out of
natural plank wood, such as oak plank. However, the treads 220,
230, and risers 240 can be made out of composites or other
preformed materials. In addition, the treads 220, 230, and risers
240 can be provided in many conventional plank widths as well as
custom sizes. Preferably, the treads 220, 230 are sized such that
the planar body portion is sufficiently sized to cover the tread
sub flooring and that the dados correspond to the thickness of the
risers. In addition, it is desirable that the depth of each dado is
selected such that the risers are free to expand within the
corresponding dado without applying a large expansion force to the
corresponding treads.
[0048] Finally, as seen in FIG. 2, a gap 250 is formed by the
arrangement of the riser 240, tread sub flooring 216 and riser
sub-flooring 218. If desired, a pad or other sound dampening
material may be placed in the gap to absorb sound during use of the
stair system 200.
[0049] Next, an exemplary method of assembling the stair system 200
will be described. After removing any old tread and/or carpeting
from the tread sub floorings 216 and riser sub floorings 218, the
rest of the stair system is attached. Generally, this process
begins at the bottom of the stair system 200 and progresses up the
stair system, although it is understood that a top-down approach
may also be used.
[0050] First, because the riser sub flooring 218 is recessed from
the end of the tread sub flooring 216, one of the plurality of
risers 240 is affixed to the end of the tread sub flooring 216
using adhesive and/or fasteners. Because this riser 240 is located
at the bottom of the stair system 200, it is preferably to only use
an adhesive. However, it is understood that fasteners can be used
and that fasteners can be hidden by the stair nose portion 234 of
the adjacent lower tread 230. Alternatively, depending on the
flooring that the stair system 200 rests on, that flooring may also
hide the fasteners.
[0051] As seen in FIG. 2, the riser 240 extends above the
corresponding tread sub flooring 216 such that the lower tread 230
can be fitted over the riser 240 and that the dado 236 receives the
riser 240 therein. The lower tread 230 can be affixed to the tread
sub flooring 216 using fasteners and/or adhesives. Preferably, the
planar body portion 232 is affixed with adhesive while the fasters
(not shown) extend through the second dado 238 into the tread sub
flooring 216. In this manner, the lower tread 230 can reliably be
mounted to the tread sub flooring 216, while allowing the fasteners
to be hidden from view by the riser 240 inserted at the back of the
lower tread 230.
[0052] Specifically, the next riser 240 is attached to the tread
sub flooring 216 located above the second dado 238. The riser 240
can be attached to the second dado 238 and/or the tread sub
flooring 218 using adhesive. As noted previously, the riser 240 may
also be attached using fasteners. This process is repeated with the
remaining lower treads 230 until the top of the stair system 200 is
reached.
[0053] As seen in FIG. 2, the upper most riser 240 extends above
the corresponding tread sub flooring 216 such that the upper tread
220 can be fitted over the riser 240 and that the dado 226 receives
the riser 240 therein. The upper tread 220 can be affixed to the
tread sub flooring 216 using fasteners and/or adhesives. Because
there is no second dado provided in the upper tread 220, a planar
finish is achieved.
[0054] As mentioned previously, the spaces 250 between the risers
240 and the riser sub flooring 218 may be filled with pads or other
sound absorbing material. Depending on the accessibility of the
spaces, the pads may be inserted before securing the corresponding
riser 240 to the tread sub flooring 218 or after the riser 240 is
secured to the tread sub flooring (e.g., one edge of the stair
system 200 is temporarily exposed.)
[0055] Because the second exemplary stair system 200 will most
likely be used to replace existing stairs with old tread and/or
carpeting, the stair system 200 will probably be supported by walls
on both sides of the stair system to hide the space 250 between the
riser 240 and the riser sub flooring 218.
[0056] The previously described stair systems allow for quick and
easily assembly by minimizing the number of components provided for
the stair system. In addition, the treads and risers may be
prefabricated such that stair systems can be modular designs.
Furthermore, the above stair systems allow old tread and/or carpets
to be replaced without removing the entire stair system.
[0057] The invention thus being described, it will be obvious that
the same may be varied in many ways. Such variations are not to be
regarded as a departure from the spirit and scope of the invention,
and all such modifications as would be obvious to one skilled in
the art are intended to be included within the scope of the
following claims.
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