Note: Descriptions are shown in the official language in which they were submitted.
1 ,
STAIR TREAD COVER
BACKGROUND
The present disclosure relates generally to protective coverings, and more
particularly
to a stair tread cover for protecting stairs and other surfaces during
construction, moving,
painting, or other activities, and a method of manufacturing the stair tread
cover.
The process of building out an area or constructing a building occurs in many
phases.
During this process, a number of different types of workers are required to
complete the
construction in stages. As a result, contractors frequently damage stairs,
floors, countertops,
and other finished work in the process of completing other tasks and moving in
and out heavy
equipment.
During the last stages of house or building construction, and after the floor
and edging
materials already have been installed, finish work such as painting, caulking,
finish carpentry,
and appliance and lighting fixture installation is typically done. This finish
work can often
cause significant damage to plastic laminates, linoleum, hardwood, ceramic
tiles, and carpets
before the building is finished, sold, or moved into. Heavy tools, caulking
and paint buckets,
and appliance edges are particularly damaging, especially when moved up or
down stairs.
Traditionally, the only protection, if any, given to floors and/or steps
during the final
stages of construction has been a thin fabric drop cloth or a thin plastic
sheet such as the 0.002-
inch-thick self-adhesive plastic sheet. These materials help protect against
minimal paint or
caulking splatters and soil on workers' feet, however, such materials do not
protect against
more severe gouges, scrapes, abrasion, or other damage and breakage due to
impact of objects
or moving of equipment/tools. Additionally, fabric throw rugs or moving van
style blankets
can be used, but these absorb liquids, snag and catch on appliances, and do
not protect against
sharp and forceful impact. Also, these covers are bulky and heavy to transport
and store and
can move or slip on a stair surface, thus potentially creating problems during
use.
During construction, painting or other activities, it is often desirable to
protect stairs by
using surface protectors. However, in instances where a drop cloth or plastic
sheet becomes
unusable such as, for example, from tearing or from shifting off of or away
from the desired
stair area, the drop cloth or plastic sheet must be removed, replaced or
repositioned, costing
the contractor(s) time.
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1
In many cases, especially when construction involves walking or carrying
equipment
or supplies up and down steps, drop cloths or plastic sheets are not always
sufficient in
protecting the stairs, particularly when the stairs are finished or carpeted.
For example, the
size and shape of most drop cloths are often larger than the area to be
covered, and are therefore
also difficult to clean. Additionally, the removal of drop cloths or plastic
sheets often results
in the unintentional spreading of dirt, debris or paint back onto the stair
surfaces that the
covering was designed to protect.
Furthermore, drop cloths are not only bulky and difficult to install, but are
also prone
to folding, slipping on the stair surface, creasing or bunching, and forming a
tripping hazard to
contractors.
Non-limiting examples of existing prior art protective surface covers are
described in
United States Patent No. 6,640,501, and United States Patent Application Nos.
US
2008/0066389 and US 2011/0135869.
In view of the current state of protective coverings, there is a need for a
protective
covering which is adaptable to stairs, which is easy to use, protects a stair
surface against sharp
and forceful impact, protects the exposed edges of stairs, and which can be
easily and
conveniently fitted to existing and/or future stairs such that the stairs can
still be used while
covered with the protective covering.
BRIEF DESCRIPTION
The present disclosure relates to a stair tread cover for protecting stairs
and other
surfaces during construction, moving, painting, or other activities, and a
method of
manufacturing the stair tread cover. A stair tread is generally configured to
cover at least
one step in a staircase. The stair tread cover includes at least a front
portion and a back portion.
The front and back portion each have a top surface and a bottom surface. At
least one adhesive
strip can be positioned on the bottom surface of the front portion of the
stair tread cover, and
at least one grip strip can be positioned on the top surface of the front
portion of the stair tread
cover.
In another and/or alternative non-limiting aspect of the disclosure, the front
portion of the stair tread cover is positionable on the step to protect the
stair tread and
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the back portion is positionable on the step to protect a stair riser of the
step in the
staircase.
In another and/or alternative non-limiting aspect of the disclosure, the stair
tread
cover can include a first sheet of material that includes the front portion
and a second
sheet of material that includes the back portion, wherein the first and second
sheets of
material are connected together.
In another and/or alternative non-limiting aspect of the disclosure, the stair
tread
cover can include at least one reinforcement strip positioned on the top
surface of the
stair tread cover.
In another and/or alternative non-limiting aspect of the disclosure, the front
portion of the stair tread cover includes a top panel configured to protect
the stair tread
and a front panel configured to protect a stair nosing of the step. The back
portion can
include a vertical panel configured to protect a stair riser of the step. In
addition, at least
one recess can be included on the top surface of the front portion. The
recess, when used,
.. is adapted to receive the at least one grip strip. Moreover, at least one
recess can also be
included on the bottom surface of the front portion that is adapted to receive
at least one
adhesive strip.
In another and/or alternative non-limiting aspect of the disclosure, the front
portion of the stair tread cover includes at least one portion of an increased
thickness.
The at least one portion of increased thickness can be formed from one or more
layers.
In another and/or alternative non-limiting aspect of the disclosure, there can
be
provided a set of stair tread covers that can be suitable for covering a
plurality of the
steps in a staircase.
In another and/or alternative non-limiting aspect of the disclosure, there is
provided a method of forming a stair tread cover suitable for covering at
least one step in
a staircase. The method includes: a) providing at least one sheet of material
having a
perimeter; and, b) machine-forming the at least one sheet of material into a
front portion
and a back portion.
In another and/or alternative non-limiting aspect of the disclosure, there is
provided a method of: (i) positioning the front portion on the step to protect
a stair tread
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of the step in the staircase, and (ii) positioning the back portion to protect
a stair riser of
the step in the staircase.
In another and/or alternative non-limiting aspect of the disclosure, there is
provided a method of: (a) providing a first sheet of material having a
perimeter, (b)
machine-forming the first sheet of material into the front portion, (c)
providing a second
sheet of material having a perimeter, (d) machine-forming the second sheet of
material
into the back portion, and, (e) connecting the second sheet of material to the
first sheet
of material. The front portion is positionable on the step to protect a stair
tread of the
step in the staircase and the back portion is positionable on the step to
protect a stair riser
of the step in the staircase.
In another and/or alternative non-limiting aspect of the disclosure, the
method of
machine-forming the first sheet of material further includes the steps of: (1)
scoring the
first sheet of material to form at least one crease aligned generally parallel
to an edge of
the perimeter of the first sheet of material; and, (2) folding the first sheet
of material
along the at least one crease to form a first panel and a second panel on
either side of and
foldably connected along the at least one crease.
In another and/or alternative non-limiting aspect of the disclosure, the step
of
machine-forming the first sheet of material further includes the step of
impressing the
first sheet of material to form a recessed zone on the top surface of the
first sheet of
material. Additionally, the step of machine-forming the second sheet of
material can
further include the steps of: i) scoring the second sheet of material to form
at least one
crease aligned generally parallel to an edge of the perimeter of the second
sheet of
material; and, ii) folding the second sheet of material along the at least one
crease to form
a first panel and a second panel on either side of and foldably connected
along the at least
one crease.
In another and/or alternative non-limiting aspect of the disclosure, the
method can
further include the steps of: i) applying an adhesive strip to a bottom
surface of the front
portion of the stair tread cover; and, ii) applying a grip strip to a top
surface of the front
portion of the stair tread cover.
In another and/or alternative non-limiting aspect of the disclosure, there is
provided a stair tread cover suitable for covering at least one step in a
staircase. The step
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includes at least a stair tread and the stair tread cover includes a front
portion comprising
a first sheet of material having a perimeter, a top surface and a bottom
surface; a back
portion connectable to the front portion, the back portion comprising a second
sheet of
material having a perimeter, a top surface and a bottom surface; at least one
adhesive
strip positioned on the bottom surface of the front portion of the stair tread
cover; and, at
least one grip strip positioned on the top surface of the front portion of the
stair tread
cover. The first and second sheets of material are connected to one another.
In addition,
at least one reinforcement strip can be positioned on the top surface of the
front portion
of the stair tread cover.
In one non-limiting object of the present disclosure, there is provided a
stair tread
cover suitable for covering at least one step in a staircase, wherein the step
includes at
least a stair tread, and the stair tread cover includes a front portion and a
back portion,
the front and back portion each comprising a top surface and a bottom surface.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover that includes at least one adhesive strip
positioned on the
bottom surface of the front portion of the stair tread cover.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover that includes at least one grip strip positioned
on the top
surface of the front portion of the stair tread cover.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover wherein the front portion is positionable on the
step to protect
the stair tread and the back portion is positionable on the step to protect a
stair riser of
the step in the staircase.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover wherein the stair tread cover comprises a first
sheet of
material that includes the front portion and a second sheet of material that
includes the
back portion, the first and second sheets of material being connected
together.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover that includes at least one reinforcement strip
positioned on
the top surface of the stair tread cover.
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In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover wherein the front portion comprises a top panel
configured
to protect the stair tread and a front panel configured to protect a stair
nosing of the step.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover wherein the back portion comprises a vertical
panel
configured to protect a stair riser of the step.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover that includes at least one recess on the top
surface of the front
portion adapted to receive the at least one grip strip.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover that includes at least one recess on the bottom
surface of the
front portion adapted to receive the at least one adhesive strip.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover wherein the front portion of the stair tread
cover comprises
at least one portion of an increased thickness.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover wherein the at least one portion of increased
thickness is
formed from one or more layers.
In another and/or alternative non-limiting object of the present disclosure,
there is
.. provided a plurality of stair tread covers suitable for covering a
plurality of steps in a
staircase.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a method of forming a stair tread cover suitable for covering at
least one step in
a staircase comprising a) providing at least one sheet of material having a
perimeter, and
b) machine-forming the at least one sheet of material into a front portion and
a back
portion.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a method that includes the steps of: c) positioning the front portion
on the step
to protect a stair tread of the step in the staircase, and d) positioning the
back portion to
.. protect a stair riser of the step in the staircase.
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In another and/or alternative non-limiting object of the present disclosure,
there is
provided a method that comprises providing a first sheet of material having a
perimeter;
machine-forming the first sheet of material into the front portion; providing
a second
sheet of material having a perimeter; machine-forming the second sheet of
material into
the back portion; and, connecting the second sheet of material to the first
sheet of
material, and wherein the front portion is positionable on the step to protect
a stair tread of
the step in the staircase and the back portion is positionable on the step to
protect a stair
riser of the step in the staircase.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a method of scoring the first sheet of material to form at least one
crease aligned
generally parallel to an edge of the perimeter of the first sheet of material,
and folding
the first sheet of material along the at least one crease to form a first
panel and a second
panel on either side of and foldably connected along the at least one crease.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a method of impressing the first sheet of material to form a recessed
zone on the
top surface of the first sheet of material.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a method of scoring the second sheet of material to form at least one
crease
aligned generally parallel to an edge of the perimeter of the second sheet of
material, and
folding the second sheet of material along the at least one crease to form a
first panel and
a second panel on either side of and foldably connected along the at least one
crease.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a method of applying an adhesive strip to a bottom surface of the
front portion
of the stair tread cover, and applying a grip strip to a top surface of the
front portion of
the stair tread cover.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover suitable for covering at least one step in a
staircase, the step
including at least a stair tread, the stair tread cover comprising a front
portion comprising
a first sheet of material having a perimeter, a top surface and a bottom
surface; a back
portion connectable to the front portion, the back portion comprising a second
sheet of
material having a perimeter, a top surface and a bottom surface; at least one
adhesive
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strip positioned on the bottom surface of the front portion of the stair tread
cover; and at
least one grip strip positioned on the top surface of the front portion of the
stair tread
cover, and wherein the first and second sheets of material are connected to
one another.
In another and/or alternative non-limiting object of the present disclosure,
there is
provided a stair tread cover that includes at least one reinforcement strip
positioned on
the top surface of the front portion of the stair tread cover.
These and other objects and advantages will become apparent to those skilled
in
the art upon reading and following the description taken together with the
accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference may now be made to the drawings which illustrate various non-
limiting
embodiments that the disclosure may take in physical form and in certain parts
and
arrangement of parts wherein:
FIG. 1 is an illustration according to one non-limiting embodiment of the
present
disclosure showing a perspective view of an exemplary stair tread cover made
from a
single piece of material;
FIG. 2 is an illustration showing additional features of the stair tread cover
of FIG.
1 in accordance with the present disclosure;
FIG. 3 is an illustration showing additional features of the stair tread cover
of FIG.
1 in accordance with the present disclosure;
FIG. 4 is an illustration showing additional features of the stair tread cover
of FIG.
1 in accordance with the present disclosure;
FIG. 5 is an illustration showing additional features of the stair tread cover
of FIG.
1 in accordance with the present disclosure;
FIG. 6 is an illustration showing additional features of the stair tread cover
of FIG.
1 in accordance with the present disclosure;
FIG. 7 is an illustration showing additional features of the stair tread cover
of FIG.
1 in accordance with the present disclosure;
FIGS. 8A ¨ 8C illustrate additional features of the stair tread cover of FIG.
1 in
accordance with the present disclosure;
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FIG. 9 is an illustration according to another non-limiting embodiment of the
present disclosure showing a perspective view of an exemplary stair tread
cover made
from two or more pieces of material;
FIG. 10 is an illustration showing a side view of the stair tread cover of
FIG. 9 in
accordance with the present disclosure;
FIG. 11 is an illustration according to another non-limiting embodiment of the
present disclosure showing a perspective view of another exemplary stair tread
cover
made from two or more pieces of material, where the two or more pieces of
material are
in a non-attached configuration;
FIGS. 12A and 12B illustrate additional features of the stair tread cover of
FIG.
11 in accordance with the present disclosure;
FIG. 13 is an illustration showing additional features of the stair tread
cover of
FIG. 11 in accordance with the present disclosure, where the two or more
pieces of
material are in an attached configuration;
FIG. 14 is an illustration showing additional features of the stair tread
cover of
FIG. 13 in accordance with the present disclosure;
FIG. 15 is an illustration showing additional features of the stair tread
cover of
FIG. 13 in accordance with the present disclosure;
FIG. 16 is an illustration showing additional features of the stair tread
cover of
FIG. 13 in accordance with the present disclosure;
FIGS. 17A ¨ 17B illustrate additional features of the stair tread covers of
FIGS.
1, 9, and 11 in accordance with the present disclosure, wherein a plurality of
stair tread
covers are shown; and,
FIG. 18 is an illustration showing additional features of the stair tread
covers of
FIGS. 1, 9, and 11 in accordance with the present disclosure.
DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS
Referring now to the drawings, wherein the showings are for the purpose of
illustrating various non-limiting embodiments of the disclosure only and not
for the
purpose of limiting the same, the present disclosure provides a system and
method for
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surface protection comprising a stair tread cover that provides protection to
stairs and/or
stair surfaces.
Referring now to FIGS. 1-18, the present disclosure is directed to a stair or
step
cover suitable for covering at least one step in a staircase. In traditional
staircases, each
step in the staircase may include a stair tread (i.e., a top and/or horizontal
surface of the
step) and a stair riser (i.e., a vertical face of the step). Furthermore, each
step in the
staircase may include a stair nosing (i.e., an edge of the stair tread
extending beyond the
front face of a stair riser).
In one non-limiting aspect of the present disclosure, there is provided a
stair tread
cover comprising one or more body portions 102 including a front portion 104
and a back
portion 106. The front and back portions of the stair tread cover can be
formed of a single
piece of material, as shown in the stair tread cover embodiment 100
illustrated in FIGS.
1-8, or formed from separate pieces of material, as shown in the stair tread
cover
embodiments 200, 300 illustrated in FIGS. 9-16. Additionally, in such
embodiments
where separate pieces of material are used, the front and back portions of the
stair tread
cover can be releasably connected together during use.
In one non-limiting configuration, the front portion 104 of the stair tread
covers
100, 200, and 300 described herein are optionally configured to at least
partially cover 1)
the stair top surface, and/or 2) the stair nosing. In another and/or
alternative non-limiting
configuration, the back portion 106 of the stair tread covers 100, 200, and
300 described
herein are optionally configured to at least partially cover the stair riser.
In other words,
the body 102 of the stair tread covers 100, 200, and 300 described herein
generally
includes a first panel 108 that covers a top surface of a stair tread, a
second panel 110
that covers the stair nosing, and a third panel 112 that covers the stair
riser. In another
and/or alternative non-limiting configuration, the front and/or back portions
104, 106 of
the stair tread covers 100, 200, and 300 described herein can be sized larger
than the stair
tread and/or stair riser, respectively, so as to also cover any unprotected
part of the
adjacent stair riser and/or tread. As such, the presently described stair
tread covers 100,
200, and 300 may optionally be configured to cover two, three, or more steps
in a
staircase.
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The material used to form the stair tread cover is non-limiting. The stair
tread
cover can be formed from one, two, or more different materials. In one non-
limiting
configuration, the front portion 104 the stair tread covers 200 and 300 of the
present
disclosure is formed from a first sheet of material having a perimeter and the
second
portion 106 is formed from a second sheet of material having a perimeter.
In another and/or alternative non-limiting configuration, the material used to
form
the presently described stair tread covers 100, 200, and 300 can be formed
from water-
resistant and/or liquid-proof materials. As such, in the instance a fluid
(e.g., water, paint,
etc.) is spilled on the stair tread cover, the material of the stair tread
cover is sufficiently
thick and/or sufficiently fluid-impermeable so as to inhibit or prevent the
spilled fluid
from seeping therethrough and contacting the stairs. In one specific non-
limiting
configuration, exemplary stair tread covers 100, 200, and 300 can include the
use of
fiberboard. In another and/or alternative specific non-limiting configuration,
presently
described stair tread covers 100, 200, and 300 can include the use of paper
pulp-based
material. In yet another and/or alternative specific non-limiting
configuration, exemplary
stair tread covers 100, 200, and 300 can include the use of press board
material. As
defined herein, fiberboard is a type of engineered wood product that is made
out of wood
fibers. The general types of fiberboard (in order of increasing density)
include particle
board, medium-density fiberboard, and hardboard. Plywood is not a type of
fiberboard,
as it is made of thin sheets of wood, not wood fibers or particles. Cardboard
is also not
fiberboard since it includes a corrugated layer.
In another and/or alternative non-limiting aspect of the present disclosure,
the
front portion 104 of the stair tread covers 100, 200, and 300 includes a first
crease 122.
In one non-limiting configuration, the front portion 104 of the stair tread
cover is folded
along the first crease 122 so as to provide the first or top panel 108 and the
second or
front panel 110 on either side of the first crease. In one specific non-
limiting
configuration, the front portion 104 of the stair tread covers 100, 200, and
300 is folded
along the first crease 122 such that the first or front panel 108 is
substantially
perpendicular (e.g., 85-95 ) to the second or top panel 110. As such, the
second or top
panel 110 of the front portion 104 of the stair tread covers 100, 200, and 300
can
optionally be bent, folded and/or shaped around a stair nosing. The front
portion 104 of
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the stair tread covers 100, 200, and 300 can optionally be manufactured as a
pre-formed
component. The type of machine and/or technique used to pre-form (when used)
the front
portion of the stair tread cover is non-limiting. For example, the front
portion of the stair
tread cover can optionally be formed via thermo-fitting. The size and shape of
the top
panel and front panel are non-limiting. In one non-limiting configuration, the
second or
front panel 110 (i.e., the panel which protects the stair nosing) is about 0.5-
6 inches (and
all values and ranges therebetween).
In another and/or alternative non-limiting aspect of the present disclosure,
the
front portion 104 of the stair tread covers 100, 200, and 300 optionally
includes one or
more areas 124 for at least one adhesive strip 126. The area 124 for the at
least one
adhesive strip 126 is located on a bottom surface 116 of the stair tread
covers 100, 200,
and 300. The area 124 for the at least one adhesive strip can be recessed;
however, this
is not required. If area 124 is recessed, the recess is generally less than
the thickness of
the adhesive tape. In one non-limiting configuration, the at least one
adhesive strip 126
(when used) is a rubber-like material. In another and/or alternative non-
limiting
configuration, the at least one adhesive strip 126 is a carpet tape. In
another and/or
alternative non-limiting configuration, the at least one adhesive strip 126 is
positioned
on the bottom surface 116 of the first or top panel 108 of the front portion
104 of the stair
tread covers 100, 200, and 300. The at least one adhesive strip 126 (when
used) provides
a temporary, non-slip contact between the top surface of a stair surface and
the bottom
surface 116 of the exemplary stair tread covers. Furthermore, the at least one
adhesive
strip 126 allows the stair tread covers to be usable on various types of
surfaces including,
but not limited to, hardwood surfaces, laminate surfaces, carpeted surfaces,
non-carpeted
surfaces, concrete surfaces, composite surfaces, plastic surfaces, plywood
surfaces, etc.
The temporary adhesive bond can optionally form a dust-proof, dirt-proof
and/or liquid-
proof bond between the stair tread covers and the underlying stair. As such,
during use,
dirt and/or debris can be prevented from working its way under the presently
described
stair tread covers and between the stair tread covers and the stair. The
temporary adhesive
strip can be a pre-applied adhesive strip. The at least one adhesive strip can
optionally
include a corresponding removable protective release liner 128 (FIG. 18) that,
when
removed, exposes an adhesive surface of the adhesive strip. The exposed
adhesive
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surface of the adhesive strip is designed to form a temporary (i.e.,
removable) bond with
a top surface of a stair and the stair tread cover. The temporary, adhesive
bond between
the exposed adhesive surface and the stair is designed to sufficiently hold
the stair tread
cover in position and prevent the stair tread cover from sliding or moving
relative to the
stair, while still remaining removable such that the stair tread cover can be
removed from
the stair before, during, or after use without damage to the stair.
The size, shape and quantity of the at least one adhesive strip 126 is non-
limiting.
Generally, the width of the adhesive strip is 0.25-5 inches and all values and
ranges
therebetween (e.g., 1 inch, 2 inches, 2.5 inches, etc.). The thickness of the
adhesive strip
is generally less than 0.25 inches (e.g., 0.004-0.24 inches and all values and
ranges
therebetween), and typically about 0.004-0.15 inches. In one non-limiting
configuration,
at least one adhesive strip 126 is generally positioned parallel at or near
the first fold 122
in the front portion 104 of the presently described stair tread covers to
provide a non-slip
surface at or near the step nosing (the most frequently contacted part of the
step). As can
be appreciated, one or more additional adhesive strips can be positioned
adjacent to the
adhesive strip 126 of the stair tread cover. When two of more adhesive strips
are used,
such adhesive strips are generally spaced from one another; however, this is
not required.
As can also be appreciated, the stair tread cover can optionally include
adhesive strips
positioned on other surfaces (i.e., the second or front panel 110 of the front
portion 104
of the stair tread covers) to correspond to other portions of steps (e.g.,
stair nosing, etc.)
which may be in contact with a user or equipment. For example, as shown in
FIG. 14,
adhesive strips may be positioned parallel at or near the first fold at
surface 136a and/or
perpendicular to the first fold at or near the sides 136b, 136c of the stair
tread covers. In
another and/or alternative non-limiting configuration, at least one adhesive
strip 126 is
optionally generally positioned at or within 1-2 inches of the front of the
stair tread cover.
In another and/or alternative non-limiting configuration, at least one
adhesive strip 126
is optionally generally positioned at or near perimeter surfaces 136a, 136b,
136c (FIG.
14) of the stair tread cover. The number and orientation of the one or more
adhesive strips
on the bottom surface 116 of the presently described stair tread covers 100,
200, 300 is
non-limiting. As illustrated in FIG. 7, the adhesive strip 126 is positioned
generally
parallel to the front edge of the front portion 104. The adhesive strip 126 is
also
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illustrated as extending the full width of the front panel 110. Generally, the
adhesive
strip 126 is configured to extend at least 50% the width of the front panel
110, and
typically extend at least 70% the width of the front panel 110. If more than
one adhesive
strip 126 is used and positioned along the generally same plane along the
width of the
front panel 110, the total length of the plurality of adhesive strips are
configured to extend
at least 50% the width of the front panel 110, and typically extend at least
70% the width
of the front panel 110.
In another and/or alternative non-limiting aspect of the present disclosure,
the
front portion 104 of the stair tread covers 100, 200, 300 on a top surface 114
of the stair
tread cover optionally includes one or more areas 130 for at least one grip
strip 132 to be
positioned. In one non-limiting configuration, the grip strip is a sandpaper-
like material.
In another and/or alternative non-limiting configuration, the at least one
grip strip 132 is
a grip tape. In another and/or alternative non-limiting configuration, at
least one grip
strip 132 is positioned on the top surface 114 of the first or top panel 108
of the front
portion 104 of the stair tread covers 100, 200, 300. Optionally, as shown in
FIGS. 8A-
8C, the top surface 114 of the first or top panel 108 of the front portion 104
can include
one or more recesses 134 into which the at least one grip strip 132 may be
placed. In
such a configuration, the thickness of the grip strip 132 is greater than the
thickness of
the recess 134 in the front portion 104 such that the grip strip extends
upwardly from the
top surface 114 of the front portion. The at least one grip strip 132 (when
used) provides
a non-slip contact on the top surface 114 of the stair tread covers 100, 200,
300 so as to
improve the traction and/or grip between a user's shoe and the stair tread
cover. As such,
during use, injury as a result of a person or equipment sliding on the stair
tread cover can
be reduced or prevented. The at least one grip strip 132 can be a pre-applied
grip strip.
The at least one grip strip can optionally include a removable protective
release liner (not
shown) that, when removed, exposes a top surface of the at least one grip
strip. In one
specific non-limiting configuration, the at least one grip strip 132 is a
formed of grip tape
applied to a recess 134 on the top surface 114 of the front portion 104 of the
exemplary
stair tread covers 100, 200, 300. In another specific non-limiting
configuration, as shown
in FIGS. 2, 4, and 5, for example, the at least one grip strip 132 is a formed
of grip tape
applied to the top surface 114 of the front portion 104 of the stair tread
cover 100.
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. .
The size, shape and quantity of the at least one grip strip 132 is non-
limiting.
Generally, the width of the grip strip is about 0.25-5 inches and all values
and ranges
therebetween (e.g., 1 inch, 2 inches, 2.5 inches, etc.). The thickness of the
grip strip is
generally less than 0.25 inches (e.g., 0.004-0.24 inches and all values and
ranges
therebetween), and typically 0.005-0.18 inches. In one non-limiting
configuration, a first
grip strip 132 is generally positioned parallel at or near the first fold 122
in the stair tread
cover to provide a non-slip surface at or near the step nosing (the most
frequently
contacted part of the step). As can be appreciated, one or more additional
grip strips can
be positioned adjacent to the first grip strip of the stair tread cover. As
can be appreciated,
the stair tread cover can include additional grip strips positioned to
correspond to other
portions of steps which may be in contact with a user or equipment (e.g.,
stair risers, stair
nosing, etc.). In another and/or alternative non-limiting configuration, a
grip strip is
optionally generally positioned at or within 0-3 inches (and all values and
ranges
therebetween) of the front of the stair tread cover, and typically about 1-2
inches of the
front of the stair tread cover. In another and/or alternative non-limiting
configuration, a
grip strip is optionally generally positioned at or near the perimeter of the
stair tread
cover, such as, for example, locations 134a, 134b, and 134c shown in FIG. 13.
In another and/or alternative non-limiting aspect of the present disclosure,
when
a first grip strip 132 and a first adhesive 126 are used, the first grip strip
is optionally
positioned directly above or at least partially overlaps the first adhesive on
the top surface
114 of the stair tread covers. In this regard, in another and/or alternative
non-limiting
aspect of the present disclosure, the grip strip 132 can be optionally
provided in the recess
134 on the top surface 114 of the front portion 104 and the adhesive 126 can
be optionally
provided in its own recess 136 directly beneath the grip strip recess and on
the bottom
surface 116 of the front portion, as shown in FIGS. 8A-8C. As also shown in
FIGS. 8B-
8C, which illustrate a zoomed-in view of section A from FIG. 8A, in another
and/or
alternative non-limiting aspect of the present disclosure, the grip strip and
the adhesive
can be provided as substantially solid pieces of material 132a, 126a,
respectively, as
particularly shown in FIG. 8B. Alternatively, the grip strip and the adhesive
can be
provided as one or more pieces of material 132b, 126b, respectively, as
particularly
shown in FIG. 8C. As such, during use, when a user walks on the grip strip on
the top
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surface of the stair tread cover, the weight of the user reinforces/re-engages
the temporary
bond between the adhesive on the bottom of the stair tread cover and the top
surface of
the stair tread. In prior art protective coverings which are not bonded to a
surface, the
protective covering tends to slide or be displaced from its original position.
One non-
limiting advantage of the stair tread cover of the present disclosure is that,
over time, as
users repetitively step on the grip strip, the stair tread cover is not
displaced from its
original position, unless physically removed from the position by a user.
In another and/or alternative non-limiting aspect of the present disclosure,
the stair
tread covers can also include at least one reinforcement strip positioned on
the top surface
114 of the stair tread cover. For example, the front portion 104 of the
exemplary stair
tread cover 100 optionally includes a reinforcement strip 138 adapted to
reinforce an area
of high stress and strain. In one non-limiting configuration shown in FIG. 4,
the
reinforcement strip 138 can be provided at the first crease 122 of the front
portion 104 of
the stair tread cover. In addition, or alternatively, a reinforcement strip
140 can be
provided at the second crease 142 of the back portion 106 of the stair tread
cover as
shown in FIG. 5. The at least one reinforcement strip 138, 140 (when used)
provides a
portion of stair tread cover which has significant stability and durability
reinforcement.
As such, during use, damage to the stair tread cover at or near the nose of
the stair can be
prevented. The reinforcement strip can be a pre-applied reinforcement strip.
The
reinforcement strip can thus be used to provide reinforcement and wear
resistance to the
region about first crease 122. Generally, the reinforcement strip (when used)
fully
overlies the first crease 122 and typically extends about 0.5-4 inches on each
side of the
first crease 122. As such, the reinforcement strip (when used) does not
typically cover
the full top or bottom surface of the stair tread covers 100, 200, and 300.
The
reinforcement strip (when used) when used, generally extends 70-100% the width
of the
front panel 110. The reinforcement strip (when used) generally is formed of a
fiber,
plastic or paper material (e.g., paper tape, fiber-reinforced paper tape,
plastic tape, etc.).
Generally, the reinforcement strip (when used) is secured to the front panel
110 by an
adhesive; however, other means can be used (e.g., melted seam, etc.).
The at least one reinforcement strip 138, 140 can be used for: i)
reinforcement of
the stair tread cover, and/or ii) retaining the shape of the stair tread cover
in a bent and/or
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biased position. For example, in non-limiting configuration, the stair tread
cover includes
one or more folds and/or bends wherein each of the folds and/or bends can
position a
portion of the stair tread cover horizontally and another portion of the stair
tread cover
vertically such as, for example, around a stair nosing. In such a
configuration, when a
reinforcement strip is applied at or near the stair nosing, the reinforcement
strip can: i)
provide improved stability and/or durability at or near the stair nosing,
and/or ii) at least
partially help retain the bend and/or folded shape of the stair tread cover
such that the
stair tread cover can fit snugly around the stair nosing. It can be
appreciated that the
reinforcement strip can have other or alternative uses.
The width and thickness of the at least one reinforcement strip 138, 140 is
non-
limiting. Generally, the width of the reinforcement strip is 0.25-5 inches and
all values
and ranges there between (e.g., 1 inch, 2 inches, 2.5 inches, etc.). The
thickness of the
reinforcement strip is generally less than 0.1 inches (e.g., 0.003-0.05
inches). A first
reinforcement strip is generally positioned at or near the first fold 122 in
the stair tread
cover to provide an area of reinforcement at or near the step nosing (the most
frequently
contacted part of the step). As can be appreciated, one or more additional
reinforcement
strips can be positioned adjacent to the first reinforcement strip of the
stair tread cover.
The stair tread cover can include one, two, or more reinforcement strips. In
one non-
limiting arrangement, the stair tread cover includes one reinforcement strip
positioned on
a top surface of the stair tread cover. As can be appreciated, the stair tread
cover can
include one or more reinforcement strips positioned to correspond to other
portions of
steps (e.g., stair risers, stair nosing, etc.) which may be in contact with a
user or
equipment. In another and/or alternative non-limiting configuration, a
reinforcement
strip is optionally generally positioned at or within 0-2 inches of each fold
of the stair
tread cover. In another and/or alternative non-limiting configuration, a
reinforcement
strip is optionally generally positioned at or near the perimeter of the stair
tread cover.
In another and/or alternative non-limiting aspect of the present disclosure,
the
front portion 104 of the presently described stair tread cover optionally
includes at least
one portion of an increased thickness, such as portion 150 illustrated on the
stair tread
cover 300 of FIG. 13. The increased thickness portion 150 (when used) can be
formed
from the application of one or more layers of the first material. Furthermore,
the increased
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thickness portion 150 (when used) may improve the rigidity and durability of
the stair
tread cover.
In another and/or alternative non-limiting aspect of the present disclosure,
the
front portion 104 of the stair tread cover optionally includes a plurality of
surface
projections, such as the plurality of surface projections 152 on the stair
tread cover 300
illustrated in FIGS. 11-16, for example. The one or more surface projections
152 (when
used) may be provided to at least partially improve traction as a user walks
over the stair
tread cover. The size, shape, and quantity of surface projections is non-
limiting. Thus,
when the one or more surface projections 152 are used, a user's traction may
be improved.
In another and/or alternative non-limiting aspect of the present disclosure,
the
back portion 106 of the stair tread covers 100, 200, 300 optionally includes
at least one
crease 142. The crease 142 (when used) allows the material of the back portion
of the
stair tread cover to be bent and/or folded along the crease. As can be
appreciated, the
number of creases is non-limited. The one or more creases can be used to
adjust the
height of the back portion to fit under different height stairs. In one non-
limiting
configuration, the back portion 106 of the stair tread covers includes a first
crease 142,
wherein the first crease is offset a distance inward from the end of the sheet
of material.
As such, in embodiments where the stair tread cover is made from a single
piece of
material, such as cover 100 illustrated in FIGS. 1-8, the back portion 106 of
the stair tread
cover can be folded along the first crease 142 so as to create the first or
horizontal top
panel 108 and the third or vertical stair riser panel 112 on either side of
the first crease.
In embodiments where the stair tread cover is made from two or more pieces of
material,
such as covers 200, 300 illustrated in FIGS. 9-16, the back portion or second
piece of
material 106 can be folded along the first crease 142 so as to create a first
vertical stair
riser panel 112a and a second horizontal stair riser panel 112b on either side
of the first
crease.
In such embodiments where the stair tread cover is made from two or more
pieces
of material, the second horizontal stair riser panel 112b of the back portion
106 of the
stair tread cover may be provided to: 1) protect a portion of the top tread
surface of the
step, and/or 2) provide a connection to the front portion 104 of the stair
tread cover.
Similarly, the first vertical stair riser panel 112a of the back portion 106
of the stair tread
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cover may be provided to protect the stair riser of a step. In one non-
limiting
configuration, the horizontal panel 112b is generally perpendicular (e.g., 85-
95 ) to the
vertical panel 112a during use of the stair tread cover on a stair.
In any of the exemplary embodiments described herein, the crease 142 can be
located on either the top 114 or bottom surface 116 of the back portion 106 of
the stair
tread covers. The crease 142 generally includes a respective offset from an
end of the
sheet of material. In one non-limiting arrangement, the first crease 142 is
parallel to one
end of the sheet of material. The crease can optionally be perforated and/or
water
resistant. In another non-limiting configuration, the back portion 106 of the
stair tread
cover optionally includes an additional area 144 for additional creases 146,
as shown on
the cover 100 illustrated in FIGS. 3 and 4. Based on the depth of a particular
stair, the
stair tread cover can be bent at the crease (i.e., crease 142 or one of the
additional creases
146) that provides a depth of the stair tread cover that best matches the
depth of the stair.
A creasing wheel can optionally be used to form the one or more creases in the
material of the stair tread cover. The scoring in the material includes a
depth from about
5% to about 30% of a depth of the sheet of material, typically about 10% to
20% of a
depth of the sheet of material. In one non-limiting arrangement, the scoring
in the sheet
of material includes a depth from about 14.5% of the sheet material.
Generally, the depth
of the crease is constant along the length of the crease.
The term 'crease' as used herein includes scoring or perforating the surface
of the
sheet of material. As such, the presently described stair tread covers 100,
200, 300 can
provide simultaneous horizontal (i.e. stair tread, stair nosing) and vertical
(i.e. stair riser,
stair nosing) protection within a single product. The crease (when used) is
generally
positioned 0.5 to 12 inches (and all values and ranges therebetween) from a
first end of
the sheet of material. When the first crease is formed generally parallel to
an end of the
sheet of material, the crease is generally spaced about 0.5-12 inches from the
end of the
sheet of material, typically 1-10 inches, more typically about 1.25-8 inches,
and still more
typically 1.5-6 inches.
In another and/or alternative non-limiting aspect of the present disclosure,
the
vertical panel 112 of the back portion 106 of the exemplary stair tread covers
can
optionally include one or more temporary adhesive strips (not shown) applied
thereto.
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The adhesive strip (when used) can be the same or different as the adhesive
strip
described above with reference to the first portion 104 of the stair tread
covers. The one
or more adhesive strips (when used) may be provided on the vertical panel 112
of the
back portion 106 for the purpose of preventing the vertical portion of the
stair tread cover
from collapsing over the front portion 104 of the stair tread cover and
exposing the stair
riser.
During installation, one or more stair tread covers in accordance with the
present
disclosure can be applied to one or more steps in a staircase. For example, as
shown in
FIGS. 17A-17B, a plurality of stair tread cover bodies 102a-102e can be
provided. FIG.
17A illustrates the plurality of stair tread cover bodies 102a-102e as an
exemplary
product package containing multiple stair tread covers as described herein,
and FIG. 17B
illustrates the plurality of stair tread cover bodies 102a-102e being
installed to multiple
steps in a staircase. Initially, a first stair tread cover, such as cover body
102a, is
positioned on a first step to be covered. After the first stair tread cover is
positioned on
the first step, a user can simply walk on the top surface of the stair tread
cover in the area
of the adhesive strip on the stair tread cover to complete the temporary
adhesive bonding
of the stair tread cover to the stair tread. The vertical portion of the first
stair tread cover
can be folded upwardly as to be positioned along the stair riser of the first
step. This
process can then be repeated to secure additional stair tread covers 102b ¨
102e to
additional steps. For example, second stair tread cover body 102b can then be
positioned
on a second step to be covered. After the second stair tread cover body 102b
is positioned
on a second step, a user can simply walk on the top surface of the second
stair tread cover
in the area of the adhesive strip on the second stair tread cover to complete
the temporary
adhesive bonding of the stair tread cover to the stair tread. The vertical
portion of the
second stair tread cover can be folded upwardly as to be positioned along the
stair riser
of the second step.
The use of a pre-applied temporary adhesive strip on the presently described
stair
tread covers 100, 200, 300 eliminates the need to apply a separate piece of
tape or other
adhesive over the edge of stair tread cover to secure the stair tread cover to
the step.
Additionally, using a pre-applied temporary adhesive strip also makes
installation of the
stair tread cover faster and easier.
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One non-limiting advantage of the stair tread covers 100, 200, 300 of the
present
disclosure is that the stair tread covers offer protection to various parts of
stairs within a
single product. For example, the stair tread cover of the present disclosure
protects the
1) stair tread, the actual step where a user places his/her foot as he/she
walks thereon, 2)
stair riser, a portion of a stair that is often kicked with a user's toe as
the user walks up
the stairs, and/or 3) stair nosing, the most often damaged portion of a stair.
In summary, the present disclosure is directed to stair tread covers 100, 200,
300
configured to protect selected portions of surfaces such as, for example,
stairs. The stair
tread covers can be sized to fit an individual step in a standard flight of
stairs; however,
the stair tread cover can be configured to accommodate non-standard flights of
stairs (e.g.
non-linear staircases, spiral staircases, etc.). The stair tread covers can be
a non-reusable
(i.e. one-time use) surface protector. As can be appreciated, the stair tread
covers of the
present disclosure can be used multiple times. In one non-limiting
configuration, the
stair tread covers 100, 200, 300 comprise a front portion and a back portion.
The front
portion of the stair tread covers can further comprise a first sheet of
material having a
perimeter, a top surface and a bottom surface. Similarly, the back portion of
the stair
tread cover can further comprise a second sheet of material having a
perimeter, a top
surface and a bottom surface. As can be appreciated, the stair tread covers
can also be
formed of a single sheet of material. The stair tread covers include at least
one adhesive
strip and at least one grip strip. The adhesive strip(s) are generally
positioned on a first
surface of the first sheet material so as to correspond to a stair tread.
Likewise, the grip
strip(s) are generally positioned on a second surface of the first sheet of
material so as to
correspond with a surface on which a user walks. The number of adhesive strips
and/or
grip strips may vary slightly due to the users' custom needs. The back portion
of the stair
tread cover optionally includes at least one crease, the at least one crease
configured to
allow the second sheet of material to be bent.
In another and/or alternative non-limiting aspect of the present disclosure,
there
is provided a method of forming the exemplary stair tread cover 100 described
above.
The method can comprise the steps of: 1) providing a sheet of material having
a perimeter,
2) machine-forming the sheet of material so as to form a first portion of the
stair tread
cover which complements at least the size and shape of a stair tread of a step
in a staircase,
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3) machine-forming the sheet of material so as to form the first portion of
the stair tread
cover having a portion which complements at least the size and shape of a
stair nosing of
a step in a staircase, and/or 4) machine-forming the sheet of material so as
to form a
second portion of the stair tread cover which complements at least the size
and shape of
at least a stair riser of the step in the staircase.
In another and/or alternative non-limiting aspect of the present disclosure,
there
is provided a method of forming the exemplary stair tread covers 200, 300
described
above. The method can comprise the steps of: 1) providing a first sheet of
material having
a perimeter, 2) machine-forming the first sheet of material so as to form a
first portion of
the stair tread cover which complements at least the size and shape of a stair
tread of a
step in a staircase, 3) providing a second sheet of material having a
perimeter, 4) machine-
forming the second sheet of material so as to form a second portion of the
stair tread
cover which complements the size and shape of at least a stair riser of the
step in the
staircase, and/or 5) connecting the second sheet of material to the first
sheet of material
to form the stair tread cover. The connection between the first and second
sheets of
material is non-limiting. For example, a non-releasable adhesive may be used
to connect
the first and second sheets of material.
The step of machine-forming the sheet or the first sheet of material can
further
optionally include the step of impressing the sheet material to form a
recessed zone on
the top surface of the sheet material, wherein the recessed zone is suitable
for attachment
of a grip strip.
The methods described above can also comprise the steps of: a) applying an
adhesive strip to a bottom surface of the front portion of the stair tread
cover, and/or b)
applying a grip strip to a top surface of the front portion of the stair tread
cover. The grip
.. strip can be applied within the recessed zone on the top surface of the
front portion of the
stair tread cover. Optionally, the method can further include the step of
applying an
adhesive strip to a back surface of the back portion of the stair tread cover
to provide a
temporary bond between the stair tread cover and a stair riser.
As can be appreciated, the stair tread cover can be formed of a single piece
of
material that is preformed and cut into shape.
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. .
The size of the stair tread cover of the present disclosure is non-limiting.
In one
non-limiting configuration, the vertical height of the stair tread cover is
about 2 inches
to about 20 inches, more typically about 3-10 inches, and more typically about
4- 8
inches. In one specific non-limiting configuration, the stair tread cover is 6
inches in
height. In another and/or alternative non-limiting configuration, the width of
the stair
tread cover is about 2 inches to about 48 inches, more typically about 4-36
inches, and
more typically about 6-24 inches. In one specific non-limiting configuration,
the width
of the stair tread cover is about 10- 11 inches.
One non-limiting object of the present disclosure is the provision of a stair
tread
cover that provides protection to stairs and/or stair surfaces.
Another and/or alternative non-limiting object of the present disclosure is
the
provision of a stair tread cover that includes at least one adhesive strip
used to connect
the stair tread cover to a stair tread.
Yet another and/or alternative non-limiting object of the present disclosure
is the
provision of a stair tread cover that includes at least one grip strip used to
provide a non-
slip surface to the stair tread cover.
Still yet another and/or alternative non-limiting object of the present
disclosure is
the provision of a stair tread cover which includes: 1) at least one adhesive
strip, and 2)
at least one grip strip.
Another and/or alternative non-limiting object of the present disclosure is
the
provision of a stair tread cover which includes at least one adhesive strip
that is a
pre-applied adhesive strip.
Another and/or alternative non-limiting object of the present disclosure is
the
provision of a method for forming a stair tread cover that provides protection
to stairs
and/or stair surfaces.
It will be appreciated that variants of the above-disclosed and other features
and
functions, or alternatives thereof, may be combined into many other different
systems or
applications. Various presently unforeseen or unanticipated alternatives,
modifications,
variations or improvements therein may be subsequently made by those skilled
in the art
which are also intended to be encompassed by the following claims.
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