Note: Descriptions are shown in the official language in which they were submitted.
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PRECISION BUILT STAIRCASE
This application claims priority to U.S. Provisional Application 61/374,571
filed on 08/17/2010, the entire disclosure of which is incorporated by
reference.
TECHNICAL FIELD & BACKGROUND
The present invention relates to a staircase. More specifically, the present
invention relates to a precision built staircase.
It is therefore an object of this invention to provide a precision built
staircase that
is relatively quicker and easier to assemble, has a relatively more (longer
lasting)
aesthetically pleasing appearance and utilizes relatively more precise pre-
manufactured
profiled structural stringers and pre-profiled decorative stringers than
current staircases.
It is another object of the invention to provide a precision built staircase
with an
added standard or universal skirt board and a plurality of accessories that
can be
assembled in a few minutes that are in compliance with various building codes
and
standards.
It is also an object of the invention to provide a precision built staircase
with a
plurality of components with a plurality of aesthetic embodiments that can be
manufactured on precision machinery such as a CNC router machine. (preferably
face
to face for a raw material economy from 26 to 38% for the first set of
structural stringers
and eliminate the need to make and other set when come the time to install the
decorative final staircase (another 100%)
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It is an object of the invention to provide a precision built staircase that
ensures
consistent dimensional productivity and installation at the right position
with a plurality of
winder's treads and risers set by utilizing a starter winder tread plank and a
pre-profiled
nose angled to a plurality of winder's treads that are also relatively easy to
fix, well-
aligned at the front surfacing and angled at 90 degrees to the front of the
starter winder
tread plank and are relatively quickly installable into a starter winder tread
plank slot
for a relatively better final result.
It is another object of the invention to provide a precision built staircase
that
allows relatively easy and rapid assembling and attachment of the staircase
components that includes a plurality of pre-drilled apertures and a plurality
of standard
and Universal brackets that can be glued together without any excess overflow
of glue
to a plurality of treads, risers and stringers.
It is also another object of the invention to provide a plurality of standard
and
Universal skirt board that can be temporarily or permanently used at a
plurality of
predetermined heights that are attached securely with one or more covers and
one or
more corner joints.
It is an object of the invention to provide a precision built staircase with a
plurality
of components that could be easily sold and kept in stock across all
distributors,
retailers, agents, installers, finishers and do-it-yourself suppliers on the
market.
It is another object of the invention to provide a plurality of precision
built
staircase components that can be easily stocked in a weather regulated
warehouse or
store, that includes structural stringers, decorative stringers, universal
skirt boards and
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other stair components that will not warp, curve, crack or split by using kiln
dried,
engineered composite materials and/or others.
It is another object of the invention to provide a precision built staircase
in a kit
form in a pre-assembled box that can be used as a cabinet, a closet or an
outside shell
that is also available in a pre-finished or a non-finished form.
It is another object of the invention to provide a precision built staircase
that can
utilize a plurality of different sizes, types, lengths, gages, with or without
headed nails
and screws.
It is another object of the invention to provide a precision built staircase
that is
made of composite, hard, softwood, aluminum, steel, concrete, marble, granite,
rough
or prefinished materials, or other suitable engineered materials pre-assembled
or non-
pre-assembled.
It is another object of the invention to provide a precision built staircase
that can
utilize a wide variety of glue types.
It is another object of the invention to provide a precision built staircase
and
related components that can be manufactured in any desired shape, size, and/or
dimension.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described by way of exemplary embodiments, but
not limitations, illustrated in the accompanying drawing in which like
references denote
similar elements, and in which:
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Fig. 1 is a front side perspective view of a staircase having a first tread
with a
recessed tread end cap, a new structural stringer, a new universal square, a
new
decorative stringer and a pre profiled skirt board with the new universal
square fit into
the structural stringer, in accordance with one embodiment of the present
invention.
Fig. 2 is an exploded front side perspective view of a staircase with a pre
profiled
skirt board and a decorative stringer, in accordance with one embodiment of
the present
invention.
Fig. 3 is a front side perspective view of a temporarily installed preliminary
staircase, in accordance with one embodiment of the present invention.
Fig. 4 is a side perspective view of a pair of skirt boards manufactured from
a
panel, in accordance with one embodiment of the present invention. Face to
face
Fig. 5 is a side perspective view of a pair of radius stringers manufactured
from a
panel, in accordance with one embodiment of the present invention.
Fig. 6 is a side perspective view of a pair of square stringers manufactured
from
a panel, in accordance with one embodiment of the present invention.
Fig. 7 is a side perspective view of a pair of angled outside radius stringers
manufactured from a panel, in accordance with one embodiment of the present
invention.
Fig. 8 is a side perspective view of a pair of horizontal outside radius
stringers
manufactured from a panel, in accordance with one embodiment of the present
invention.
Fig. 9 is a side perspective view of a pair of vertical outside radius
stringers
manufactured from a panel, in accordance with one embodiment of the present
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invention.
Fig. 10 is a side perspective view of a pair of winder inside radius stringers
manufactured from a panel, in accordance with one embodiment of the present
invention.
Fig.11 is a side perspective view of 4 universal squares manufactured from a
panel with a plurality of tapered apertures drilled at a predetermined angle
to receive a
plurality of screw treads and a plurality of risers pre-nailed or screwed to a
plurality of
structural stringers, in accordance with one embodiment of the present
invention.
Fig. 12 is a side perspective view of a universal square attached to a
structural
stringer, in accordance with one embodiment of the present invention.
Fig. 13 is a front side perspective view of a standard riser with a plurality
of
apertures and grooves for glue overflow, in accordance with one embodiment of
the
present invention.
Fig. 14 is front side perspective view of a dowel and spring and a top tread,
in
accordance with one embodiment of the present invention.
Fig. 15 is an overhead side perspective view of a tread with a positioned slot
to
receive a dowel of a riser, in accordance with one embodiment of the present
invention.
Fig. 16 is an bottom side perspective view of a tread with a positioned slot
to
receive a dowel of a riser, in accordance with one embodiment of the present
invention.
Fig. 17 is an overhead side perspective view of a tread and riser assembly at
a
level of a spring-dowel with a positioned slot to receive a dowel of a riser
and a groove
at a rear of tread, in accordance with one embodiment of the present
invention.
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Fig. 18 is an overhead side perspective view of a pair of grooves at a rear of
a
tread, in accordance with one embodiment of the present invention.
Fig. 19 is a top perspective view of a first winder's tread fit at a starter
winder
tread plank, in accordance with one embodiment of the present invention.
Fig. 20 is side perspective view of a winder starter plank with a plurality of
align
recessed noses of a first winder's tread, a second winder's tread and a third
winder's
tread with a decorative jacket, in accordance with one embodiment of the
present
invention.
Fig. 21 is a side perspective view of a second winder's tread fit at a winder
starter
plank, in accordance with one embodiment of the present invention.
Fig. 22 is a side perspective view of a third winder's tread fit at a winder
starter
plank, in accordance with one embodiment of the present invention.
Figs. 23 A-J are a plurality of side perspective views of a plurality of
shapes of a
plurality of pre-profiled stringers, pre-profiled decorative stringers,
standard and
universal skirt boards, standard and universal squares and bars, in accordance
with
one embodiment of the present invention.
Fig. 24 is a front side perspective view of a packing box, in accordance with
one
embodiment of the present invention.
Fig. 25 is a rear perspective view of a precision built staircase, in
accordance
with one embodiment of the present invention.
Fig. 26 is a side perspective view of a precision built staircase, in
accordance
with one embodiment of the present invention.
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Fig. 27 is an overhead side perspective view of a reversible stringer-tread
support, in accordance with one embodiment of the present invention.
Fig. 28A is a side perspective view of an attachment screw, in accordance with
one embodiment of the present invention.
Fig. 28B is a front perspective view of an attachment screw, in accordance
with
one embodiment of the present invention.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
Various aspects of the illustrative embodiments will be described using terms
commonly employed by those skilled in the art to convey the substance of their
work to
others skilled in the art. However, it will be apparent to those skilled in
the art that the
present invention may be practiced with only some of the described aspects.
For
purposes of explanation, specific numbers, materials and configurations are
set forth in
order to provide a thorough understanding of the illustrative embodiments.
However, it
will be apparent to one skilled in the art that the present invention may be
practiced
without the specific details. In other instances, well-known features are
omitted or
simplified in order not to obscure the illustrative embodiments.
Various operations will be described as multiple discrete operations, in turn,
in a
manner that is most helpful in understanding the present invention. However,
the order
of description should not be construed as to imply that these operations are
necessarily
order dependent. In particular, these operations need not be performed in the
order of
presentation.
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The phrase "in one embodiment" is used repeatedly. The phrase generally does
not refer to the same embodiment, however, it may. The terms "comprising",
"having"
and "including" are synonymous, unless the context dictates otherwise.
In accordance with these objects which will be discussed in detail below, the
present invention provides a complete line of modified stair components and,
when
assembled together with a plurality of accessories and a stair kit reduce
installation
time, achieve a relatively higher percentage savings of raw material,
manufacturing
time, and installation time with a relatively high precision.
Fig. 1 is a front side perspective view of a staircase having a first tread
with a
recessed tread end cap, a structural stringer, a universal square, a
decorative stringer
and a pre-profiled skirt board with the universal square fit into the
structural stringer, in
accordance with one embodiment of the present invention.
The invention relates to a staircase 500, more particularly, the invention
relates
to modifications and ameliorations brought to a plurality of typical staircase
components
utilized that make the staircases relatively easier to install and are
typically more
economical to manufacture saving manufacturing time, raw material and 30 to
70% of
the installation time due to the relatively high precision of preferred
machinery (e.g.
CNC router) used to produce many of the staircase components 500. When all of
the
components will be assembled, the final result will be a relatively better
temporary or
permanent fit. It will permit the re-use of the structural stringer 3
installed at the
beginning of construction permanently and only replace a rough tread 18 and a
riser 17
initially temporary installed by a plurality of chosen decorative treads 1-10
and risers
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200, a decorative stringer 4, a pre-profiled skirt board 5 and any other
desired
components, pre-finished or to be finished.
Staircases currently available on the market are mostly assembled on a job
site
and to save installation time, few distributors offer them pre-assembled which
can also
be prefinished. When assembled on a job site, most of the time, stringers 3
are cut
manually with a skill saw typically 2" x 2" x 12" which is where precision
discrepancies
occur. When the staircases are assembled at a manufacturing site, they do not
necessary have the high precision machines (CNC router) to perfectly cut the
stringers
3, 4 and other high precision components cut. Typically it's very difficult to
determine in
advance the precision squaring and leveling the walls, floors and ceiling
formed 95 % of
the time in a new building or a remodeled job site, resulting that some
percentage of
components fabricated or adjusted on site must be reprocessed, resulting in a
relatively
costly operation.
Installation of staircase 500 is considered by professional building
contractors to
be relatively complicated work. It is imperative to introduce into a
relatively large market,
products that can be installed in less time and with more efficiency and
precision.
Structural stringers 3 are a significant part of substantial saving in
manufacturing, raw
material, installation time and an attractive final long lasting aesthetic
appearance.
Regarding the stringers 3, 4 and pre-profiled skirt board 5; the
manufacturing's precision
and relative rapid execution offer distributors, retailers and others a
reasonable price
and better compliance of building codes. Structural stringers, 3, decorative
stringers 4, a
pre-profiled skirt board 5 and a plurality of winder's treads 201,202,203 can
be
manufactured in a through panel, that can also be reversible, made of many
materials
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such as engineered, laminated, plywood, composite, kiln dried or other
suitable
materials to reduce the components curving, warping, cracking, shrinking or
expanding
too much. All these elements are required to be avoided so that precise
manufacturing
at the beginning of the manufacturing process may avoid the need to reinstall
new
stringers 3, 4 when it's time to install the final permanent decorative
staircase.
Fig. 4 is a side perspective view of a pair of skirt boards manufactured from
a
panel attached face to face, in accordance with one embodiment of the present
invention.
The height of risers 47A and tread's runs 46 staying precise allows further
ameliorations to these components for an easier and quicker installation.
Fig. 6 is a side perspective view of a pair of square stringers manufactured
from
a panel, in accordance with one embodiment of the present invention.
The pair of skirt boards includes a plurality of stringer types 501,601,701,
801,
901,1001, risers 200 treads 1, 10, 18, dowels 205, springs 206, aperture 210,
slot 208,
profiles and grooves 701A, 801A.
Figs. 23 A-J are a plurality of side perspective views of a plurality of
shapes of a
plurality of pre-profiled stringers, universal skirt boards, universal squares
and bars, in
accordance with one embodiment of the present invention.
Figs. 23 A-J illustrates contact between some of the components that permit a
relatively better adjustment when assembled temporarily and/or permanently
together.
The staircase 500 attempts to correct or hide imperfections in cutting and
assembling
and/or further variations of adjacent construction components. The staircase
500
attempts to minimize the time of installation, to maximize the quality of
assembly and to
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minimize the touch-up areas. Risers 200 are attached to treads 112 underneath
through
angled apertures 208 A at specific angles typically with round headed screws
209 that
are self-drilled and tempered. Addition of a plurality of grooves to the top
of riser groove
207 or bottom front 200A permits a better grip and possibility to add glue 19
such as PL
Universal square 15 firmly maintains the desired position in regards to
temporarily or permanently attached treads 1-10, risers 200 and stringer 3.
Two pieces
of sticky and spongy material 15A are added on top of universal square 15 to
be
Fig. 19 is a top perspective view of a first winder's tread fit at a starter
winder
tread plank, in accordance with one embodiment of the present invention.
Cover joint 18a, 18 b, 18c and corner joints 2540 will time efficiently cover
a
plurality of cuts 18B at joint eliminating touch-up areas.
20 Fig. 20 is a side perspective view of a starter winder tread plank 101 a
plurality of
align recessed noses of a first winder's tread, a second winder's tread and a
third
winder's tread with a decorative jacket, in accordance with one embodiment of
the
present invention.
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Starter winder tread plank 101 assures the installation of winder's treads
1,2,3 to
firmly and accurately align each other in a plurality of predetermined single
recessed
slots 1A,2A,3A at a predetermined precise riser height desired and to tightly
attach
winder's risers 16,213,3B at right angles to the adjacent wall 550, starter
winder tread
plank 101, winder's treads 1,2,3 together.
Starter winder tread plank 101 assures the installation of winder's treads
1,2,3 to
firmly and accurately align each other in a plurality of predetermined double
recessed
slots 1A,2A,3A and to tightly attach winder's risers 16,213,3B at right angles
to the
adjacent wall 550, starter winder tread plank 101, winder's treads 1,2,3
together.
Fig. 2 is an exploded front side perspective view of a staircase 500 with a
pre-
profiled skirt board 5 and a decorative stringer 4, in accordance with one
embodiment of
the present invention.
Pre-profiled skirt board 5 will be installed relatively quickly without any
scratches
on treads or risers such as pre-finished treads or risers using a plastic tape
6, with a
resistant pre-glued 7 at one side of the plastic tape 6. The pre-profiled
skirt board 5 is
laid down over plastic tape 6 preinstalled at a wall side over treads 10 and
risers 1 then
the universal skirt board 2631 is slid-up to the front of risers 1 and is
pushed to the wall
550. One or more nails 16 or screws 19 that secure the pre-profiled skirt
board 5 to wall
550 are hid with an overlap angled molding 560. The plastic tape 6 can be
removed by
manually tearing-off the plastic tape 6. The plastic tape 6 can similarly be
utilized for
pre-profiled skirt board of a winder's set.
Fig. 3 is a front side perspective view of a temporarily installed preliminary
staircase, in accordance with one embodiment of the present invention.
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One or more tread's end cap 11, 12, 13 shown in FIG. 1 can be added at one or
both sides of tread 10 and formed recess (not shown) at a depth of the typical
length of
overpass of the decorative stringer 4 (open decorative stringer) at 50 % of
thickness
of tread and
at 100% or less of the width of treads 116. The end cap 11,12,13 can be
dimensioned
and shaped as desired and will typically be disposed on the rear of tread 113
to hide
imperfect fits, hide a vertical 902, a horizontal 802 and/or an angled outside
radius 702
of stringers 4 or simply for a decorative look. Angled square 575 of any
suitable outside
or inside shape can bring the same corrections resulting in a different
aesthetic
appearance at a lower price.
Bottom rear tread radius when tread are nosed right and or left side (to be
discussed
Pre-profiled 5 and universal skirt board 2631 adds a desired aesthetic fit and
hide
nails 16 and/or screws 19 used at top side of treads 10 and risers 1,17,200
and/or
space between the wall 550 and treads and risers, when there is, in straight
500 or
winder's installation
Fig. 19.
Fig. 21 is a side perspective view of a second winder's tread fit at a
starting
plank, in accordance with one embodiment of the present invention.
Decorative starter plank jacket 100 can be added any time after treads and
risers are installed over the rough starter plank 99 and holder of starter
plank. To build
a straight staircase 500 on-site will save from 4 to 6 hours of installation
time in contrast
to a traditional staircase and to built on site a L-shaped staircase 500 with
a set of 3
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winder's treads and risers, the saving time will be up to 6 to 9 hours in
contrast to a
traditional staircase. This relatively large time savings will be appreciated
by
professional building contractors and do-it-yourself customers who wish to
install their
own staircase.
Fig. 22 is a side perspective view of a third winder's tread fit at a staring
plank, in
accordance with one embodiment of the present invention.
Decorative starter plank jacket 100 can be added any time after treads and
risers are installed over the rough starter plank 99 and holder of starter
plank. To build
a straight staircase 500 on-site will save from 4 to 6 hours of installation
time in contrast
to a traditional staircase and to built on site a L-shaped staircase 500 with
a set of 3
winder's treads and risers, the saving time will be up to 6 to 9 hours in
contrast to a
traditional staircase. This relatively large time savings will be appreciated
by
professional building contractors and do-it-yourself customers who wish to
install their
own staircase.
Fig. 15 is an overhead side perspective view of a tread with a positioned slot
to
receive a dowel of a riser, in accordance with one embodiment of the present
invention.
Prior to installing a plurality of rough risers 17 of treads 18, structural
stringers 3
are installed at a precise position initially with glue and are then nailed or
screwed to
wall 550.
Fig. 16 is an overhead side perspective view of a tread with a positioned slot
to
receive a dowel of a riser, in accordance with one embodiment of the present
invention.
Top 207 and bottom of risers are nailed or screwed to riser height 570 of
structural stringer at an identical level to the top tread's runs 580, the top
of below riser
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which has at least one aperture, a dowel 205 or a spring-dowel 205,206 to
match the
slot 208 in the front of and underneath tread 116 to be typically nailed or
screwed in a
desired precise position.
Fig. 17 and Fig. 18 are an overhead side perspective view of a tread and riser
assembly at a level of a spring-dowel with at least one groove and or a radius
at a rear
of a tread with a positioned slot to receive a dowel of a riser, in accordance
with one
embodiment of the present invention.
Top 207 and bottom of risers are nailed or screwed to riser height 570 of
stringer
at an identical level to the top tread's runs 580, the top of below riser
which has at least
one aperture, a dowel 205 or a spring-dowel 205,206 to match the slot 208 in
the front
of and underneath tread 116 to be typically nailed or screwed in a desired
precise
position. The rear of tread 113 includes a tread radius 118 and a tread groove
119
Fig. 17 is an overhead side perspective view of a tread and riser assembly at
a
level of a spring-dowel with a groove at a rear of a tread with a positioned
slot to receive
a dowel of a riser, in accordance with one embodiment of the present
invention.
When the rough and/or decorative stair components are ready to be installed, a
reversible universal square 15 could be secured by gluing, nailing or screwing
to the
inside structural stringer 3 at the back of staircase 500. The universal
square 15
underneath the rough tread 18 is set in place and pushed to the back of the
riser 17 that
is already secured in place. It is significant to install at least two
previously described
auto adhesive resilient material pieces 15 A to the top of the universal
square 15 and at
least one, if desired, to the middle vertical front of the universal square 15
to be used.
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This process can be repeated at all triple stringer contacts 3 to the left or
right if there
are more than 2 structural stringers.
Fig.11 is a side perspective view of 4 universal squares 15 manufactured from
a
panel with a plurality of reversed tapered apertures drilled at a
predetermined angle to
receive a plurality of screw treads and a plurality of risers pre-nailed to a
plurality of
structural stringers, in accordance with one embodiment of the present
invention.
After termination of these operations, all rough treads 18 and risers 17 can
be
torn-out and ready to receive the new pre-finished or to be finished desired
risers 200
and treads 10 to structural stringers 3 and pre-profiled decorative stringers
4. These
components can be tighten with suitable appropriated screws from the back of
staircase
500 through the reversed taper apertures 215 at the underneath and the back of
universal square 15 to the underneath of treads and to the back of the riser.
Any nailing
and or screwing to top of treads and risers that will be eventually hidden,
will be
permitted and facilitate the securing of treads and risers from the back of
universal
squares 15.
Fig. 13 is a front side perspective view of a standard riser with a plurality
of
apertures and grooves for glue overflow, in accordance with one embodiment of
the
present invention.
When an end-user desires a permanent and solid installation, glue is typically
applied to the structural stringers 3 at the suggested grooved shape at
tread's runs 580
and/or to the riser's heights 570, top of risers length 207 and/or bottom
front riser's
grooves 202B to the riser to be tighten to the rear of tread 113 or the rear
of tread slot
or grooves 119 to be tighten to front bottom of standard riser 200 B through
the desired
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pre-drilled apertures 203B at the bottom of the riser with appropriated
screws,
introduced at the back of the standard riser rear bottom. The typical screws
to be used
for the staircases' installation are a plurality of rounded head screws 209
that are self-
drilled forming angled apertures 208A and tempered of suitable appropriated
lengths. (a
complete kit of screws needed for the installation of chosen staircase will be
available
for sale) and other ways to save time and errors.
Fig. 10 is a side perspective view of a pair of winder inside radius stringers
manufactured from a panel, in accordance with one embodiment of the present
invention.
Standard holder bar (not shown) will come at a plurality of predetermined
lengths
and typically has the same dimensions as the top of the longer side of the
universal
square 15 and will be secured at the rear of the universal square 15 when more
strength is needed to attach treads to tread's runs of stringer (e.g. Winder's
tread 1, 2, 3
to winder's stringers 1001).
Fig. 12 is a side perspective view of a universal square attached to a
structural
stringer, in accordance with one embodiment of the present invention.
Similar suitable techniques to form or drill angled apertures and tapered
apertures will be applied as well including securely screwing treads and
risers to tread's
runs of stringers 580 with a plurality of previously described pieces of
sticky and spongy
material 15A placed between stringers 580.
Any corner joints 18 b, 2542, 2570, cover joints 18 c, 2540, 2560, 2585, or
starter winder tread plank 101 will be used to hide
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jointed cuts (good or bad), nails 16 or screws, acting as a recess for pre-
profiled and
universal skirt board 5, pre-profiled decorative stringers 4, treads 10 and
risers 1-200.
Some molding with angled overlap 560 will be hid as well, over and at the side
of these
prefinished or non-prefinished components.
Fig. 5 is a side perspective view of a pair of inside radius stringers
manufactured
from a panel, in accordance with one embodiment of the present invention.
Some pre-shaped inside square cover 13 with or without an inside 502 or an
outside radius 702,802,902 can be added to bottom rear tread outside of
decorative
stringer 4 and/or square angles 602 to match and cover manufactured inside 502
and
the bottom shape of rear tread when tread are nosed at side(s).
Fig. 7 is a side perspective view of a pair of angled outside radius stringers
manufactured from a panel, in accordance with one embodiment of the present
invention.
The pre-shaped inside square cover 13 also includes outside radius 702,802,902
or square angles 602 at the rear and or bottom of lateral overlapped tread's
nose.
Fig. 8 is a side perspective view of a pair of horizontal outside radius
stringers
manufactured from a panel, in accordance with one embodiment of the present
invention.
The pre-shaped inside square cover 13 also includes outside radius 702,802,902
or square angles 602 at the rear and or bottom of lateral overlapped tread's
nose.
Fig. 9 is a side perspective view of a pair of vertical outside radius
stringers
manufactured from a panel, in accordance with one embodiment of the present
invention.
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The pre-shaped inside square cover 13 also includes outside radius 702,802,902
or square angles 602 at the rear and or bottom of lateral overlapped tread's
nose.
The back of staircase 500 has to be finished and frequently the professional
contractor installer or painter is required to return several times to
completely finalize
the staircase construction, which can be relatively costly. One way to
eliminate this is to
supply standard backing panels (not shown) to be adjusted to the back of
staircases to
be typically equally cut at the jobsite at each side, to be properly fit, pre-
finished and
fabricated from any suitable material available. The backing panel of
staircase can be
pre-finished or non-prefinished, plain or with any suitable types of printed,
pressure
printed, molded designs, grooved or with any suitable designs, textural finish
or
composition of products adaptable to the back of staircases stringers 3 or 4.
Many
different types of molding (not shown), shaped or design, can be added to all
joints and
or walls, floors or ceilings adjacent to staircases. If the stairs, backing
panel and
moldings are pre-finished, there is no need to have other professionals come
back to
finalize the construction of the staircase, resulting in a substantial savings
of time and
money with a relatively more convenient decorative final result. The
decorative backing
panel of the staircase can be installed with a plurality of nails or a
plurality of screws
with or without glue with preferably some backing cross-member installed
between
stringers when necessary and desired sound padding can be added between
standard
backing panel and back of treads and risers. Any molding should be installed
in a
floating orientation secured to the wall and should allow for shrinking and
expansion
variations of structure that do not affect the final aesthetic appearance.
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Stringers riser's radius 502 could be disposed on riser rear bottom 131
typically
to
decorative angled standard risers to assemble with angled decorative
stringer's risers'
predetermined height and if the height of riser 200 is too wide, the
predetermined height
of the riser can be cut at a desired height minus radius 502 or at 15 degrees
from the
front bottom riser predetermined height. Typically all risers 200 that are
installed
permanently as standard of any length should be pre-cut at each end at a 45
degrees
angle or more and more typically at a 47 degrees angle 590, where the fit with
decorative stringer riser height pre-angled cut will be typically suitable and
if the riser
angle is not necessary can be cut square as needed without creating an
inadequate fit.
Fig. 14 is front side perspective view of a dowel and spring and a top tread,
in
accordance with one embodiment of the present invention.
Some others modifications to risers 200 and treads 10 will attach them at the
right position quickly, precisely and tight fit together temporarily and/or
permanently
(with or without glue) to underneath front of tread 200 A. One of these is, at
least one
aperture 203A, 203B located at the approximate middle of the top riser length
and plus
or minus half-thickness of the riser to insert a dowel 205 or preferably a
spring 206 plus
an
appropriated dowel 205 in wood or in other material to the bloc riser at the
desired
position when dowel 205 is engage in limited slot 208 length at the same
distance underneath the tread nose. The dowel 205 is introduced in the slot
208
by the pressure action of the spring pushing the dowel 205. When both the
dowel 205
and the slot 208 are connected together, the standard riser 200 is ready to be
screwed
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securely underneath the tread 116 without slipping out of slot, through angled
apertures
208A pre-drilled from back of riser 200 B to top of riser with suitable
appropriated
screws 209. Risers 200 has at least one marker line 201A.
This eliminates steel squares or pre-drilled blocs onsite, usually used by
professional contractors. The preferred shapes at the top of the riser should
be a W-
shaped section Fig. 23 F and or triple V-shaped section Fig. 23 J (e.g. a
double big V-
shaped section and small V-shaped section disposed in middle of riser). This
triple V-
shape will allow glue to be disposed with a gun at the middle V-shaped section
to
overflow in double V-shaped section of each side when the treads and risers
will be
tighten together. At the bottom front 200A of standard riser 200 at least one
groove and
typically 3 grooves are provided to permit adhesion and accommodate overflow
of glue
when rear of bottom tread and bottom front riser are secured together through
at least
one aperture of a plurality of apertures 203B that are pre-drilled and are
accommodated
with one or more suitable appropriated screws 209.
Typically when installers assemble a temporary staircase on a job site are
replaced by a decorative staircase, rough treads 18 and risers 200 are nailed
to a
structural stringer 3, however this is not possible when decorative threads
and risers are
installed. The staircase 500 remedies this and allows a pre-profiled universal
skirt board
to be installed at the wall over the nails and/or screws and potential wrong
cuts and then
be hidden by the thickness of the universal skirt board.
Fig. 24 is a front side perspective view of a packing box, in accordance with
one
embodiment of the present invention.
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Packing box 2400 is provided to transport any staircase components that need
to
be protected when carried to the job site. Some components are relatively long
such as
stringers 3, 4 and the universal skirt board 2631 and are also relatively
fragile to carry.
More specifically when prefinished, the packaging box 2400 should be solid and
very
protective and typically is relatively very costly. The packing box 2400 can
also have a
second use as a cabinet and/or closet with or without a door or a cover 2430
that can
also be split into two or more sections 2410 and 2420 that can also be usable
as
furniture (e.g. a cabinet for tools and accessories or a shoes cabinet open
shell) or any
other desired suitable utilities or applications, pre-finished or non-pre-
finished. The
packing box 2400 can potentially save money, prevent environmental waste, as
well as
protect staircase components to be delivered and serve as a strong marketing
tool for a
manufacturer, or any intervenient in distribution and sale of staircases and
or other
domains. The dual purpose packing box 2400 can be adapted to any type of
suitable
products to be carried needing suitable appropriated protection. The packing
box 2400
can be made of any suitable type of material, at any suitable desired
dimensions,
engineered design, or other needed specification. Different kits of shells,
doors and
accessories associated with the packing box 2400 will be available on request
and can
be customized with specified specifications as well.
Fig. 25 is a rear perspective view of a back of the staircase, in accordance
with
one embodiment of the present invention.
The back of the staircase 500 is attached to a first wall 2510, a second wall
2520
and a third wall 2530. The back of the staircase 500 is attached between the
first wall
2510 and the second wall 2520 and behind a third wall 2530. A skirt board
starter joint
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2540 attaches the back of the staircase 500 with the third wall 2530 typically
at each
corner of the back of the staircase 500. There is also a corresponding cap
2542
disposed on each of the skirt board starter joints 2540 to protect the skirt
board starter
joints 2540. A winder starter plank 2550 attaches the back of the staircase
500 to the
first wall 2510. A cap 2552 is also disposed on the winder starter plank 2550
to protect
the winder starter plank 2550. A middle skirt board joint 2560 attaches the
back of the
staircase 500 to the second wall 2520. A cap 2562 is disposed on the middle
skirt board
joint 2560 to protect the middle skirt board joint 2560. An outside skirt
board corner joint
2570 also attaches the back of the staircase 500 to the second wall 2520. A
cap 2580 is
disposed on the outside skirt board corner joint 2570 to protect the outside
skirt board
corner joint 2570. A tread rim extender tread 2590 additionally attaches the
first wall
2510 to the back of the staircase 500. A tread rim 2595 is disposed underneath
the
tread rim extender tread 2590 to further attach the back of the staircase 500
to the first
wall 2510. A reversible molding 2575 also attaches the back of the staircase
500 to the
first wall 2510. A skirt board ender joint 2585 is disposed underneath the
reversible
molding 2575 to further attach the back of the staircase 500 to the first wall
2510. A cap
2587 is disposed on the skirt board ender joint 2585 to protect the skirt
board ender joint
2585.
Fig. 26 is a side perspective view of a precision built staircase 500, in
accordance with one embodiment of the present invention.
The staircase 500 includes the reversible molding 2575 which is disposed on
top
of the staircase 500. There is also a cap 2610 on the top of the staircase
500. The skirt
board inside corner joint 2540 is underneath the cap 2610. A tread rim bloc
2620 is
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disposed underneath the skirt board start joint 2540. A tread rim extender
2630 is
vertically and horizontally attached to each vertical portion 2640 of each
step 2642 the
staircase 500. The tread rim extender 2630 is attached to the vertical portion
2640 with
a plurality of screws 2644. The tread rim 2595 is then provided on the distal
end 2650 of
the horizontal portion 2652 of each step 2642. The universal square 15 secures
the
vertical portion 2640 and the horizontal portion 2652 together. The overlap
angled
molding 560 has a pair of ends 562 with a flange 2660 provided on the ends 562
of the
overlap angled molding 560. The skirt board ender joint 2585 and cap 2587 are
provided at the bottom of the staircase 500.
Fig. 27 is an overhead side perspective view of a reversible stringer-tread
support 2700, in accordance with one embodiment of the present invention.
The structural stringer 3 has a plurality of grooves 2710 disposed on top of
the
structural stringer 3. The grooves 2710 are typically convex 2712 but can be
any
suitable shape. The grooves 2710 permit glue to overflow and spill on either
side of the
grooves 2710 and permit a better and larger grid surface, while also providing
a better
hold and attachment at the right level. There are one or more tape apertures
2720
provided as well.
Fig. 28A is a side perspective view of an attachment screw 209, in accordance
with one embodiment of the present invention.
The attachment screw 209 includes a threaded portion 2810, a screw head 2820
and a non-threaded portion 2830. The threaded portion 2810 is disposed on a
rear half
2802 with a distal end 2803 of the attachment screw 209. The round head 2820
is
disposed on a proximal end 2804 of the attachment screw 209. The round head
2820
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can be a Phillips head shaped 2822 or any other suitable shaped screw head.
The non-
threaded portion 2830 is disposed on a front half 2806 of the attachment screw
209 and
accommodates a thickness of any tread. There is also a self-drill end 2840
disposed on
the end of the distal end 2803. Right now on the market there is not a screw
for this
application that is more then gage number 9. Gage number 10 or higher may be
used
in the application.
Fig. 28B is a front perspective view of an attachment screw 209, in accordance
with one embodiment of the present invention. The threaded portion 2810, the
screw
head 2820 and the non-threaded portion 2830 and their components of the
attachment
screw 209 are the same as illustrated and described in Fig. 28A. The screw
head 2820
can be a Phillips head shaped 2822 or any other suitable shaped screw head as
previously described in Fig. 28A.
Installation of the staircase and its components can be done from the top of
the
staircase to the bottom of the staircase, eliminating the need for an
installer to walk on
the tread during the installation, which is typically done during the
installation. This also
allows the installer to work alone without a helper during the installation
utilizing a top to
bottom installation.
The precision of the structural stringer and the prefabricated components
assembled together permit the installation of a prefabricated skirt board
after the
structural stringer, tread and riser are installed, something that is
typically impossible to
do with a regular installation with material currently on the market.
Most engineered skirt boards are typically installed in two or three parts
because
single engineered skirt boards of a suitable length are typically not
available and are
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very difficult to carry and time consuming to manufacture especially with a
fit-at-joint
assembly. These engineered skirt boards are also less aesthetically attractive
than
other relatively shorter skirt boards for end-user customers.
In Fig.26 the universal skirt board will accommodate and accept a relatively
wide
variation of riser heights up to +/- 7/8ths of the height of the tread rim
while preserving
an aesthetically pleasing installed skirt board.
The packing box will permit the delivery of relatively longer components such
as
full length skirt boards and full length molding without anxiety regarding the
components
being broken or damaged while being transported.
There is also a tread groove disposed at the rear of the tread to accommodate
any glue spillage and overflow and therefore relatively more glue for a
potentially
stronger attachment. A plurality of multiple grooves accommodate any glue
spillage or
overflow that are typically installed at the middle rear portion of the tread
that are firmly
secured to the riser and tread together to minimize the possibility of glue
spillage and
overflow over the tread top. The one or more grooves at the top of the riser
also have
the same function of catching glue spillage and overflow.
Any of the one or more grooves provide a strong, permanent and tight
attachment of any adjacent components when the components are made of wholly
or
partly engineered products, such as OSB, particleboard, fiberboard, plywood,
LVL, LSL,
softwood and other materials that can easily possibly break, split or allow
for a screw or
nail to be easily torn-off or removed.
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The standard stringer tread support can also be reversible. A plurality of
grooves
permit glue to overflow and spill on either side of the grooves and permit a
better and
larger grid surface while also providing a better hold and attachment.
Typically the grooves are disposed around the sides of the stringer that are
cut
with a shot leveler to lock down, align and set the reversible standard
stringer tread
support relatively quickly at a desired height and level. Similar to all of
the components
of the staircase, the grooves disposed around the stringer can be relatively
quickly and
easily installed.
While the present invention has been related in terms of the foregoing
embodiments, those skilled in the art will recognize that the invention is not
limited to
the embodiments described. The present invention can be practiced with
modification
and alteration within the spirit and scope of the appended claims. Thus, the
description
is to be regarded as illustrative instead of restrictive on the present
invention.
27
