U.S. patent application number 11/846284 was filed with the patent office on 2009-03-05 for modular staircase system and kit for erecting a staircase.
Invention is credited to Joseph S. Miller.
Application Number | 20090056245 11/846284 |
Document ID | / |
Family ID | 40405304 |
Filed Date | 2009-03-05 |
United States Patent
Application |
20090056245 |
Kind Code |
A1 |
Miller; Joseph S. |
March 5, 2009 |
MODULAR STAIRCASE SYSTEM AND KIT FOR ERECTING A STAIRCASE
Abstract
The present invention relates to a novel method and modular
assembly for producing a staircase. The modular staircase allows
one with little to no skill to quickly and easily order and install
a modular staircase at reasonable cost with no specialized
technical skill necessary.
Inventors: |
Miller; Joseph S.; (Raleigh,
NC) |
Correspondence
Address: |
PASSE' INTELLECTUAL PROPERTY, LLC
1717 BRASSFIELD RD.
RALEIGH
NC
27614
US
|
Family ID: |
40405304 |
Appl. No.: |
11/846284 |
Filed: |
August 28, 2007 |
Current U.S.
Class: |
52/188 ;
52/745.19; 52/745.2 |
Current CPC
Class: |
E04F 11/035 20130101;
E04F 11/108 20130101 |
Class at
Publication: |
52/188 ;
52/745.19; 52/745.2 |
International
Class: |
E04F 11/035 20060101
E04F011/035 |
Claims
1. A premeasured kit of parts for a staircase assembly the parts
comprising: a) an inner skirt board having a selected number of
steps; b) an outer skirt board having a selected number of steps
corresponding to the inner skirt board; c) a plurality of riser
boards corresponding to the number of steps; d) a plurality of
tread boards corresponding to the number of steps; e) a plurality
of tread sub-support plates corresponding to the number of steps;
wherein the tread sub-support plate is designed to coordinativly
attach the inner skirt board, the outer skirt board, the riser
boards and the tread boards and wherein the parts are predrilled
with attachment and alignment holes.
2. A kit of parts according to claim 1 wherein the staircase is
curved.
3. A kit of parts according to claim 1 wherein the sub-support
plate is pre-attached to the tread.
4. A kit of parts according to claim 1 which further comprises a
sub-support plate cleat.
5. A kit of parts according to claim 5 wherein the tread is made of
a material which cannot be screwed or nailed to the tread
sub-support plate.
6. A kit of parts according to claim 1 wherein at least 2 of the
parts are notched to fit together.
7. A kit of parts according to claim 5 wherein the riser and the
skirt boards are notched to fit together.
8. A kit of parts according to claim 1 which further comprises a
set of one or two temporary walls for constructing the staircase
prior to construction of or attachment to permanent walls.
9. A method of assembling the kit of parts of claim 1 comprising
attaching the skirt boards and riser boards to the sub-support
plate followed attaching the tread to the sub-support plate.
10. A system for providing a modular staircase assembly comprising:
a) measuring the space intended for the staircase; b) manufacturing
an inner skirt board, and outer skirt board, treads, risers and
tread sub-support plates to construct a staircase to fit the
measured space; c) drilling attachment and alignment holes in the
parts of b) such that the parts can be aligned and coordinativly
attached to the tread sub-support plates to form the staircase.
11. A system according to claim 10 wherein there is also provided
one or more support cleats.
12. A system according to claim 10 wherein the sub-support plate is
pre-attached to the tread.
13. A system according to claim 10 wherein at least 2 of the parts
are notched to fit together.
14. A system according to claim 10 comprising attaching the skirt
boards and riser boards to the sub-support plate followed by
attaching the tread to the sub-support plate.
15. A system according to claim 10 wherein the tread is made of a
material which cannot be nailed or screwed to the tread sub-support
plate.
16. A system according to claim 10 wherein the staircase is
assembled by attaching the staircase to one or two temporary walls.
Description
COPYRIGHT NOTICE
[0001] A portion of the disclosure of this patent contains material
that is subject to copyright protection. The copyright owner has no
objection to the reproduction by anyone of the patent document or
the patent disclosure as it appears in the Patent and Trademark
Office patent files or records, but otherwise reserves all
copyright rights whatsoever.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to staircases and their
fabrication for use on a commercial or residential site. More
particularly the present invention relates to a staircase system
which is pre-configured and precision cut to selected
specifications, off site, under factory conditions and comes to the
installation site in the form of a kit with improved construction
and assembly techniques for such modular staircase systems. In at
least one embodiment the staircase of the present invention is at
least partially curved.
[0004] 2. Description of Related Art
[0005] Staircases are composed of a number of standard components.
Where there is a curved stair involved, each step has a curved
inner radius smaller that the curved outer radius. Staircases,
including curved staircases, are either supported by walls
underneath the staircase or supported by attachment to the walls on
either side of the staircase or, in many cases, supported by a wall
on one side and self supported on the other side. In some
embodiments of staircases, the staircase is free-standing or
self-supported, only being supported by the floors and the
balconies they are attached to at the top and bottom of the
staircase.
[0006] Staircases are constructed within a 3 dimensional space
defined by the standard plane limitations of the 3 axes, X, Y and Z
However, it is usual within the trade that 4 measurements are
needed or at least taken when building a staircase. The X axis is
the horizontal plane and relates to the width of the staircase. The
width is usually predefined in blueprints or based on the space
available or in some cases by the person ordering the staircase.
Typically, there are standard widths in the trade and it is very
common that widths of 42 and 48 inches are used for the standard
staircase. One skilled in the art would be able to determine the
width and allow for things such as edging railings and the like.
The Y axis is the depth plane, and represents the measurement from
the very front of the staircase to the back of the staircase and is
called the run. The run of stairs is divided equally to produce a
number of treads that fits within the space (often determined by
statutory code). The Z axis is the vertical measurement and is the
floor to floor measurement used to figure the height of the risers.
The floor to floor measurement is referred to as the rise. One last
measurement is usually made or determined called the rake. The rake
is the diagonal line from the end of the rise (top floor) to the
end of the run on the first floor where the stair starts. While
this measurement can be determined from the rise and run, it is
useful to have the measurement as a guide during building of the
staircase. The actual measurements can be extremely difficult to
determine, even by those of great skill in the art, especially in
residential construction, because of the use of various floor to
ceiling heights, building codes, variation in the thicknesses of
materials, errors in wall placements and the general minute
inaccuracies introduced into the area around the staircase during
construction due to cutting and measuring accuracy limitations.
Cutting errors in the construction of the staircase itself add even
further difficulties in constructing a staircase.
[0007] In order to build a staircase in place first stringers are
glued together by using glued together wooden laminate. The
stringers are attached to the support wall and measurements are
made for the riser and tread and notches which are hand cut into
the edges of the stringers for receipt of the riser and tread
across the stringers. Then measurements are taken on the individual
stringers for fabricating the individual riser and tread members
for the staircase. The complexity and precision entailed in this
conventional staircase fabrication technique renders it, as a
general rule, a method only usable by skilled woodworking artisans
and not by a general construction contractor.
[0008] Many of the problems limitations and disadvantages of
building a staircase in place have been attempted to be overcome by
a wide variety of modular staircase systems. While each of them has
some advantage over fabrication of a staircase in place, each
retains much of the complexity at the onsite installation and thus
may still not be satisfactory for installation by a contractor let
alone a do-it-yourselfer.
[0009] In U.S. Pat. No. 4,413,460 to Gerlach, issued Nov. 8, 1983
there is disclosed do it yourself spiral staircase having a hollow
steel tube. The individual treads are distributed along the column
between spacer sleeves in an open type construction. While this is
good for this type of staircase, it does not address the standard
residential curved staircase made with natural products such as
wood, lumber, stone, granite or slate. In U.S. Pat. No. 4,583,335
to Morellini, issued Apr. 22, 1986 there is disclosed a modular
staircase system wherein the framework of the staircase is produced
by assembly of modular components paired with the next in sequence
so as to form a bearing structure for the single stair tread. The
stairs and components are slotted and designed to be built up as
you go however since the components are standardized they do not
take into consideration variations in walls and the like and can
easily not fit a given situation.
[0010] In U.S. Pat. No. 5,613,341 to Skillern issued Mar. 25, 1997
there is disclosed a modular method of producing a staircase
comprising supply of one-piece stair modules each having a front
and back wall wherein the modules are placed together. Likewise in
U.S. Pat. No. 5,502,933 also to Skillern there is disclosed a
modular staircase comprising stair modules which are all
identical.
[0011] In U.S. Pat. No. 6,516,574 to Couture issued Feb. 11, 2003
there is a staircase comprising a permanent framing made of
metallic stringers. In addition there is a plurality of non-wooden
step supports adapted to be mounted to the stringers. This modular
method relies heavily on non-wooded nontraditional support means
and still has the difficulty in adjusting the staircase to size at
the location do to the use of non-adjustable metallic pieces.
Lastly in US published patent application number US2006/0156649 to
Smith and filed Jan. 19, 2005 there is disclosed a modular stair
case comprising longitudinal modules that are stacked together to
longitudinally telescope together and form successive portions of a
staircase. The amount of wood and alignment necessary for this
method makes it almost impossible for someone without a great deal
of skill to actually set in place.
[0012] There is still therefore a great need for a modular
staircase system that once provided is easy to install by an
unskilled or lightly skilled worker that will meet the needs of
each individual situation for installing such a staircase.
SUMMARY OF THE INVENTION
[0013] It has been discovered in the present invention that a
modular component comprising custom cut pieces with predrilled
screw holes can be lined up and assembled in place by the do it
yourselfer or other construction person desiring to assemble a
staircase but having little skill in the area of such assembly. By
cutting the pieces to a specific shape and providing a subtread
plate each portion can be installed without the skill and trauma
necessary for prior art modular staircase systems.
[0014] Accordingly, in one embodiment, the present invention
relates to a component staircase with predrilled screw holes that
can be aligned between parts. Each of the parts is custom made for
the individualized staircase, predrilled so that all that is
necessary is to align matching holes and nail or screw the pieces
together to assemble the staircase in place.
[0015] In one embodiment the present invention relates to a
premeasured kit of parts for a staircase assembly the parts
comprising: [0016] a) an inner skirt board having a selected number
of steps; [0017] b) an outer skirt board having a selected number
of steps corresponding to the inner skirt board; [0018] c) a
plurality of riser boards corresponding to the number of steps;
[0019] d) a plurality of tread boards corresponding to the number
of steps; [0020] e) a plurality of tread sub-support plates
corresponding to the number of steps; wherein the tread sub-support
plate is designed to coordinativly attach the inner skirt board,
the outer skirt board, the riser board and the tread board and
wherein the parts are predrilled with attachment holes.
[0021] In another embodiment of the invention there is a system for
providing a modular staircase assembly comprising: [0022] a)
measuring the space intended for the staircase; [0023] b)
manufacturing an inner skirt board, and outer skirt board, tread,
riser and tread sub-support plates to construct a staircase to fit
the measured space; [0024] c) drilling attachment and alignment
holes in the parts of b) such that the parts can be aligned and
coordinativly attached to the tread sub support plates to form the
staircase.
[0025] These and other objects of the present invention will be
clear when taken in view of the detailed specification and
disclosure in conjunction with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1a is a perspective view of an assembly of the
invention showing the tread sub-support plate and its attachment
without the tread attached.
[0027] FIG. 1b is a perspective view of the complete assembly of an
embodiment of the kit of parts of the invention.
[0028] FIG. 2a is a perspective view of an assembly showing the
attachment of a skirt board and tread sub-support plate to the
skirt boards.
[0029] FIG. 2b is an angle view of an optional cleat reinforcement
for the tread sub-support plate.
[0030] FIG. 3a is an underneath view showing the reinforcement
cleat of FIG. 2a.
[0031] FIG. 3b is a side view of an assembly of the invention as
seen through the inner skirt.
[0032] FIG. 3c is a side view of an alternate assembly of the
present invention.
[0033] FIG. 4 is a 3-dimentional wedge defining rake, run, rise and
width of the staircase.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The general description of the invention and how to
manufacture and assemble the kit of parts of the present invention
is stated in the Brief Summary above. This detailed description
defines the meaning of the terms used herein and specifically
describes embodiments in order for those skilled in the art to
practice the invention. The above interests in successfully
providing an easy to assemble kit of parts for a staircase can
readily be seen from the disclosure which follows and are met by
the present invention. This detailed description defines the
meaning of the terms used herein and specifically describes
embodiments in order for those skilled in the art to practice the
invention.
[0035] As used herein the term "premeasured" or "measuring" refers
to taking measurements on site where the staircase is to be
assembled. The measurements include the X, Y and Z (i.e. the rise,
run, width and rake) measurements sufficient to construct a
staircase. Other measurements including height of the skirt boards,
curve radius, selected woods, or any other measurement desired in
constructing the staircase of the invention can also be made at the
same time and are also included in the measurement process. The
measurements will need to be of sufficient accuracy by one skilled
in the art such that the staircase can designed and precut to be
assembled and slid into place without significant adjustment of the
parts of the kit. This includes appropriate adjustments for the
errors, misalignments and the like in the space to be installed and
as such each staircase becomes a custom production kit. Within
reason measurements should be within a quarter inch or so in order
to insure a good fit.
[0036] Skirt boards comprise the sides of the staircase and can be
on a wall side supported by a wall or on an open side and self
supported. The skirt boards have steps built into it to accommodate
the riser boards, sub-support plate and tread of the present
invention. The skirt boards are in general spaced such that they
achieve the measured or desired width of the staircase.
[0037] In a straight staircase the inner and outer skirt boards are
the skirt boards on either side of the staircase and the inner and
outer skirt boards generally refer to the same thing just the
opposite sides from one another. Where a staircase is curved the
"inner skirt board" is the skirt board that forms the smaller
radius on the curve and the "outer skirt board" is the skirt board
that forms the larger radius of the curve.
[0038] Where the skirt board is on an open side it can have a
supporting wall or otherwise be self supported. If the skirt board
is on a closed side, that is, against the wall, the skirt board
will be attached to a wall. So, therefore, staircases can be
totally self supporting, have both sides supported by walls or have
one side supported by a wall while the other side is self supported
(as is frequently the case with curved staircases).
[0039] A skirt board is, in one embodiment, built up from pieces of
quarter inch plywood to a thickness of about 3/4 inch to attach to
a wall. To make a skirt-board self supporting, additional layers of
plywood are added to a thickness of around 2 to 3 inches, however
one skilled in the art can make the skirt board as thick as
necessary and using any kind of wood built up to a desired
thickness that is within the skill in the art. Often times local
code will determine the actual thickness of a supporting skirt
board and one skilled in the art can make the appropriate
adjustments in thickness as well as step height for the riser board
(US national building codes allow a maximum of 81/4 inch in height
for a riser board). Normally, each skirt board is as long as is
necessary to go from a given floor to the next landing and a skirt
board herein can mean multiple boards sufficient to go from the
bottom to the top of the staircase. A 3/4 inch skirt board gives
the support to the staircase until walls are built under the
staircase or the staircase is attached to the wall. The present
invention also provides "temporary walls` which are designed and
pre-cut for each staircase kit. The temporary walls are used to
support the staircase while it is being constructed and usually
stay attached until the staircase can be attached to or supported
by the permanent walls. In the case of self-supporting stairs
(which can be both sides), the skirt boards are built thick enough
to produce a beam thick enough to support the staircase between its
start on the floor and where it attaches on the floor above. In the
case of a curved staircase, the skirt boards would be appropriately
curved by attaching them to the tread sub-support plate designed to
meet the wall in most cases. Such measurements, in view of the
disclosure herein, are within the skill in the art. One of the
primary reasons for an embodiment using layers of thin plywood for
the skirt boards rather than one solid piece is that these thinner
pieces can easily be bent to the shape necessary for the staircase
(especially when curved) either in the factory or when putting the
kit of parts together and can be adjusted more easily to fit the
given space of the staircase.
[0040] The skirt board, when attached to a wall is normally visible
and larger than a self supporting skirt board which is positioned
beneath the tread and risers. One skilled in the art would be able
to size both self supporting and wall supporting skirt boards in
view of the teaching herein.
[0041] As used herein the "riser boards" are the upright front
board for each step that is positioned under each tread and between
the two skirt boards. The "tread" boards are the piece of wood of a
step that one actually steps on. In other words, the steps top
portion. In the case of a straight staircase, the tread will be
rectangular but in the case of a curved staircase the sides of the
tread (and or the return ends as needed for the type and style of
curve) will have an inner and outer radius corresponding to the
curve in the staircase itself and the wall or area the staircase is
curving around. In one embodiment the tread board can be notched
into the skirt boards to facilitate alignment and prevent changes
in the steps over time.
[0042] As used herein the "tread sub-support plates" is a secondary
piece of wood or other supporting material positioned underneath
each tread at the front section. It is also positioned between the
skirt boards and the top of one riser board and the bottom of the
riser board of the next step (rear) up the staircase. The tread
sub-support plate has each of the other components attached to it
by predrilled holes and appropriate fasteners such as wood screws
or nails as well as additional glue which is used to hold the parts
together and add additional strength by having more areas to screw
and glue which the customer uses to assemble the premeasured kit of
parts. The staircase can be built without the tread installed
initially with the use of the tread sub-support plate. This also
would allow for the use a material that are not normally considered
structural materials for treads such as reclaimed antique heart
pine that has nail and or spike holes as well as large loose knots
and could not be used as a tread without the tread sub-support
plate of the invention. By coordinativly attaching (screwing or
nailing through the pre-drilled holes) and the gluing each of the
pieces by the predrilled alignment/attachment holes, the various
parts of the kit can be assembled. In a further embodiment, the
risers are notched in a manner that accepts the skirt boards and
this further adds to a secured construction. The tread can be
installed as the stair is being constructed or further in the
construction process with the use of the sub-tread plate. In the
case of a curved staircase, the curve is formed or created as each
of the parts is screwed together and the kit assembled. In the
embodiment where notching is also used the parts can further be
aligned quickly and easily without long terms problems due to
swelling, shrinkage or shifting.
[0043] As used herein "coordinativly attach" refers to the process
of manufacturing each of the parts of the staircase in such a
manner that the parts will fit together to make a staircase. In one
embodiment, the attachment of the parts is coordinated around
attachment to the sub-tread plate. While a number of means have
been taught in the past, the present invention relates to the novel
use of holes that are predrilled and coordinativly attach the
pieces of the staircase to the tread sub-support plate. In one
embodiment numbered or otherwise indicated holes match with which
other numbered or indicated holes to facilitate alignment and
proper matching of parts. Notching of each or some of the parts can
also be done to further assist in aligning, attaching and holding
the pieces in position for gluing and screwing and nailing.
[0044] The terms "predrilled for alignment and attachment" refers
to the drilling of holes in corresponding parts of the kit that
will attach such that they not only will attach but also align
properly upon assembly. In an additional embodiment, the parts, for
example the tread and risers can be notched for an even better fit.
Further information can be observed in the embodiments shown in the
figures which follow. As used herein, "holes" refers to use of a
drilling mechanism to place a hole for use in attachment of the
wooden parts of the stairs. By aligning holes from two parts a
nail, screw, staple or the like can be driven into the two aligned
holes for attachment and to insure alignment. Optionally glue can
be used between the parts to further strengthen the attachments.
Again in an embodiment each piece is screwed into the sub-support
plate. Normally, such holes are starter holes made slightly smaller
than the nail or screw or the like to be used as an attachment
means. Where attachment means such as bolts are used, the hole
could be slightly bigger than the bolt to be threaded through the
hole. The present invention thus produces a staircase kit of parts
which is much easier to assemble than previous staircase kits, is
as sturdy but in most cases uses far fewer parts and materials to
assemble making it less complicated and easier to understand the
assembly process.
[0045] In one embodiment, an additional feature will be an
alignment attachment cleat that is positioned on the sub-tread
plate that will further help align and attach the parts. The cleat
can be a one by one or the like positioned between the tread
sub-support plate and the riser. One embodiment is disclosed in the
figures which follow. One skilled in the art could include other
variations of the cleat alignment/attachment board as further shown
in the drawings. The cleats of the invention could be attached by
any convenient means such as nails, screws and construction
glue.
[0046] The process for putting together the kit of parts of the
invention starts with measuring the space for the staircase. The
present invention requires that accurate measurements be taken of
the space and the appropriate kit of parts for the staircase be
drafted out and manufactured based on those plans. Given the kit of
parts and the disclosure and drawings herein, one skilled in the
art of staircase construction could easily make the appropriate
measurements (within about 1/4 inch of error) followed by
manufacturing the inner and outer skirt board(s), the treads,
risers and tread sub-support plates and such optional parts such as
the cleats, returns and cove molding for each kit of parts. By
drilling alignment /attachment holes then, one of very low skill
need only align all the holes in corresponding parts and screw or
nail or the like the parts in order to coordinativly assemble the
kit of parts produced to form a staircase. In one embodiment, all
parts are attached to the central tread sub-support plates. This
method makes it possible to manufacture a large number of
staircases quickly and easily without having to stand over the
manufacture and installation of each staircase on location. It also
releaves the manufacturer of the stairs of the assembly process for
the staircase which now can be done on a do it yourself basis and
even ordered through warehouse hardware stores and the like without
fear of the normal problems associated with the building of a
staircase, even from previously known kits of parts which will end
up with a large cost savings to the eventual purchaser or user. In
one embodiment, the holes are numbered or otherwise indicated
matching such that matching holes have matching numbers allowing
some one assembling the staircase to match the parts in the kit and
easily assemble the parts without having to figure out which part
goes with which other part. In yet another embodiment the kit of
parts is supplied with written, CD or video instructions for
assembling the kit of parts. In other embodiments the kit of parts
includes an assembly instruction sheet that could also in another
embodiment show drawings including exploded drawings of the
staircase construction.
[0047] The parts of the kit of parts in the present invention can
be made essentially entirely of wood (absent decorative or other
functional attachments). However, the addition of the novel tread
sub-support plate means the tread material could be other than wood
such as granite, stone or slate. The type of woods, treads
thicknesses, exact measurements and sizes of the steps, number of
steps and other construction details is well within the skill in
the art of staircase construction in view of the disclosure herein.
It is also, in another embodiment possible to include wall plates
curved for the proper radius of a curved staircase, bands for
curved balconies, landing treads to match curved balconies,
railings, returns trim and any other part associated with a
staircase and the like with the kit of parts to further complete
the staircase where desired.
[0048] Now referring to the drawings, FIG. 1a is a view of the kit
of parts of the present invention without the treads attached, the
kit of parts having been partially assembled in this figure up to
the point of addition of the treads. In this view, outer skirt 2
would be attached to a wall to support the staircase but the wall
has been left out for clarity. In this view, the skirt 2 is shown
as a 3 ply 2a, 2b and 2c. Attached to both outer 2 the inner skirt
3 are three riser boards 5 and three tread sub-support plates 4. In
the kit of parts, both of the skirt boards 2 and 3, the end of
riser 5 and sub-tread plate 4 have holes drilled in the end of the
boards with matching holes 10 (shown in FIG. 1a for inner skirt 3
and 2b for outer skirt 2) which match up and are screwed or nailed
together with the use of wood and construction glues.
[0049] Likewise in FIG. 1a the riser boards 5 are screwed to the
tread sub-plate 4 with a series of predrilled holes 10 that have
had screws or nails used to attach them. In one embodiment the
holes 10 are in the upper front side 15 (showing placement for
attachment to riser 5) of the riser board and on the long wide edge
of the sub-plate (shown in another figure where riser 5 in FIG. 1a,
is predrilled with holes 10 at location 15 and are attached as in
FIG. 2b).
[0050] Also in FIG. 1a the inner skirt board 3 is shown closest to
the viewer in this embodiment and like the outer skirt 2 it has had
holes 10 pre-drilled and the screws or nails used to attach it to
the riser 5 and sub-support plates 4. This configuration would then
be a supported and skirt board 2 attached to the wall while skirt
board 3 would have a wall built underneath it, to be followed by
attachment of the treads (see FIG. 1b). Since the thickness is
hidden in this view it is not shown however like the inner and
outer skirt boards it would most likely be 3 ply.
[0051] FIG. 1b is the kit of parts completely assembled into a
staircase 1. Shown again is outer skirt 2 and inner skirt 3 which
form the left and right halves of the supported staircase 1. Risers
5 can also be seen in this figure. In this embodiment, however, the
sub-support plate 4 is not seen since tread 6 with attached return
21 now sits on top of it and has been glued and screwed or the like
in place. In an alternate embodiment, not shown the sub-plate 4
shown in FIG. 1 is attached to the tread 6 first and then attached
to the rest of the components of the kit. One teaching a customer
to build the kit of parts into staircase 1 could easily design the
parts to be assembled in a number of different orders as long as
the proper alignment/attachment holes 10 have been drilled. As can
now be seen, the present invention will be much simpler to assemble
than any of their previous modular staircases and will be as simple
to build on site as in the stair masters shop.
[0052] FIG. 2a is a view of the kit of parts with only a few of the
pieces of staircase 1 in place while assembling the kit of parts.
Outer skirt 2 is shown but in this view holes 10 are shown which
correspond to the edge of the sub-plate board 4 and riser board 5.
The tread 6 from FIG. 1 can be screwed or nailed from the bottom
(as to hide attachment) right into the sub-plate 4 and/or the riser
5. In an alternate embodiment, the tread 6 can be attached to both
of the skirts in a manner similar to all the other attachments. In
this view the hidden edges of the boards can be seen. The front
edge of the sub-plate 30, the top edge of riser 31, the top edge of
inner skirt 32 and the front edge of inner skirt 33 (where the
riser is attached) can all be seen in the view of the incomplete
staircase 1.
[0053] FIG. 2b shows an isolated riser 5 attached to a sub-support
plate 4. Shown are the alignment attachment holes 10 as in previous
views. In this view however, the edge of riser 51 which, in an
embodiment, is notched to accept skirt board 3, is shown as is the
edge of sub-plate 52. Accordingly, the alignment attachment holes
10 previously hidden are shown. In this view, optional cleat 20 is
shown forming support between the riser 5 and sub-support plate 4
further strengthening the staircase construction in anticipation of
addition of the tread 6. The cleats can be extremely important when
the tread material is other than wood which cannot be screwed in
for attachment such as stone, granite or slate. The cleat 20 in
this embodiment is the entire length of the skirt 5 and sub-plate 4
interface but one skilled in the art can determined a desired
length from the disclosure here. Further, the cleat 20 can be
pre-attached to either the riser or sub-support plate to aid in
alignment and attachment of the parts.
[0054] FIG. 3a shows a view of the underneath of an embodiment of a
portion of the assembled kit of parts of the invention wherein the
cleat 20 is shown in another embodiment attaching to the
sub-support plate 4 and riser 5. In this embodiment, the cleat does
not extend the entire length of the attachment position of the two
pieces of the kit but still acts as an extra support and alignment
means. Other cleats can be seen in this embodiment a
skirt/sub-tread plate cleat 24 is shown as is skirt/riser cleat 22.
As with the other cleats shown the cleat adds strength and
alignment features to the present kit.
[0055] FIG. 3b shows a side view of a portion of the assembled kit
of parts. The view in FIG. 3b is as seen from the outer skirt 2
side, and for purposes of this view, the outer skirt 2 is drawn as
if transparent. As can be seen in this view, a series of risers 5
attach to a series of sub-support plates 4 by alignment of holes
10. A screw 11 is shown attaching the two pieces that has been
threaded through the two holes 10. In this embodiment tread 6 is
aligned and attached to the sub-support plate and due to the
molding 60 on tread 6, the screw 11 and screw hole 10 are hidden
from view after assembly of the staircases.
[0056] FIG. 3c shows yet another embodiment of the present
invention. FIG. 3c is a side view embodiment showing two steps
without the inner and outer skirt boards. In this view treads 6 are
shown again sitting on top of two each tread sub-support plate 4.
Risers 5 are also shown from the side as well. In this view there
is a cross-section of a riser/sub-support plate cleat 20 and a
riser/skirt-board backing cleat 23. Also shown is a cross section
of cove molding 60 which hides the screws 11 from view. The other
alignment/attachment holes are left out for clarity but would be
made as in FIGS. 1a and 1b or as one skilled in the art sees fit
for example putting holes in the side of tread 6 for attachment to
corresponding holes in the skirt boards.
[0057] In FIG. 4 there is shown a 3 dimensional wedge depicting the
basic measurement characteristics of a staircase. The width is
shown as 72 and is the width of the staircase between risers. The
run 71 of the staircase is the front to back measurement of the
staircase. The staircase height 70 is the distance between floors r
the overall height of the staircase and lastly the staircase rake
73 is the diagonal formed by the staircase.
[0058] When the kit of parts is provided to the eventual purchaser,
all the parts are essentially flat boards. They can be stacked,
numbered, and tied together for ease of transport and for keeping
the kit of parts organized. Since the kit can be transported in
less space, the cost of transporting the staircase is substantially
less than previous staircase kits. As described earlier, the parts
can be coordinativly numbered in order to facilitate the assembly
by one not skilled in the art of assembly of a staircase. In one
embodiment, one could number the parts and then instruct the
assembler how to match the numbers to construct a staircase.
[0059] As can be seen from the partial and complete construction
view of the kit of parts, once provided with the kit, one can align
and attach each of the pieces in a sequential manner to build an
entire staircase of the desired size. One skilled in the art would
not be limited by the specific examples and would be able to vary
the size number etc of the staircase corresponding to the scope of
the invention taught herein. Accordingly, the figures are not
intended to be limiting the claims that follow.
[0060] The above description and example are for the purpose of
teaching the person of ordinary skill in the art how to practice
the present invention and it is not intended to detail all those
obvious modifications and variations of it which become apparent to
the skilled worker upon reading the present invention description.
It is intended, however, that all such modifications and variations
be included within the scope of the present invention, which is
defined by the following claims. The claims are intended to cover
the claimed steps and components, in any sequence, consistent with
the present invention that is effective to meet the objectives
herein intended unless the context specifically indicates to the
contrary.
* * * * *