Stringer and Step Support Kit for Stairways
The present staircases are constructed of modular stringers for the on-site Installation of the staircases in a residential, commercial or industrial setting. Kits for erecting the staircases will include matingly or cooperatively coupling step support units defining the staircase stringers, a set of steps adapted to be mounted thereon, as well as various finishing elements and modules to provide a finished look to the completed staircases. The staircases presented herein include self-supporting staircases, linear staircases, curling or spiralling staircases and adjustable variations thereof. Each kit is designed to provide an easy installation of the staircases while providing for the erection of solid finished staircases.
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The present invention relates to stairways and, more particularly, to modular stairways made of pre-fabricated components such as stringers, step supports, railings, etc., typically in the form of a kit for assembly on site.
BACKGROUND OF THE INVENTIONTypically, staircases are completely produced on site with the various wood components being cut to size as the staircase is progressively erected on site.
Also, it has been proposed to completely assemble a staircase in the factory such that a pre-assembled staircase is delivered to the construction site for direct and easy installation thereat. Such a modular staircase is disclosed in the Canadian Application No. 2,149,981 naming Raymond Couture as inventor and laid-open for public inspection on Nov. 24, 1995.
Furthermore, in Canadian Application No. 2,276,988 also naming Raymond Couture as inventor and laid-open for public Inspection on Dec. 30, 1999, a modular staircase is proposed that includes a permanent framing made of metallic stringers and vertically extending step supports that are secured along the stringers. Each step support includes upper and front flanges adapted to be secured respectively to a tread and to a riser of each step of the staircase. If the staircase has a partly exposed side, various decorative or finishing wooden components, including treads, risers, false or decorative stringers, mouldings, etc., are provided to cover any exposed structural metallic framework and particularly the stringers.
Also, in the U.S. Pat. No. 4,422,270 naming Leopold Lapoine and Donat Pelletier as inventors and issued on Dec. 27, 1983, a modular, self supporting flight of stairs is proposed. The flight of stairs described therein comprises at least one pair of stringer units for supporting at least one tread thereon and bolted thereto, the stringer units each comprising a side plate and a fixation plate extending outwardly therefrom and parallel thereto for fixing a fixation of a first unit to a side plate of an adjacent unit by riveting or bolting. A two-part stringer unit comprising Intersecting oblong slots allows for step height adjustments.
Finally, in the U.S. Pat. No. 2,593,683 naming G. W. Lyons as inventor and issued on Apr. 22, 1953, a vertically adjustable staircase is proposed. The flight of stairs described therein comprises sectional stringers formed of prefabricated sheet metal tread-supporting plates, each plate comprising a vertical body portion, two vertical and parallel longitudinal flanges perpendicular thereto and a horizontal rectangular top flange for supporting a tread thereon and bolted thereto. One of the longitudinal flanges of a given plate comprises a plurality of sets of perforated holes for combining with a set of corresponding perforated holes in an adjacent longitudinal flange of an adjacent plate thereby providing adjustable fastening means therefor.
SUMMARY OF THE INVENTIONMore specifically, in order to address the above and other drawbacks and in accordance with the present invention, there is provided a modular stringer for a staircase, the stringer comprising at least two matingly coupled step support units defining the stringer, said step support units each comprising a main structural body, a first mating structure extending substantially laterally from a first lateral side thereof and a second mating structure extending substantially laterally from an opposing lateral side thereof, said first mating structure of said step support unit being adapted to be matingly coupled with an adjacent second mating structure of an adjacent step support unit such that said adjacent unit is vertically offset therefrom.
Still in accordance with the present invention, there is provided a step support unit to be matingly coupled with at least one structurally similar adjacent step support unit such that said adjacent unit is vertically offset therefrom, the unit for the construction of a modular stringer for a staircase, the step support unit comprising a main structural body, a first mating structure extending substantially laterally from a first lateral side thereof and a second mating structure extending substantially laterally from an opposing lateral side thereof, said first structure comprising at least one mating element and said second structure comprising at least one complementary mating element complementary to said mating element of said first structure and vertically offset therefrom.
Still in accordance with the present invention, there is provided a kit for erecting a staircase between an upper and a lower structure, the kit comprising at least two modular stringers each comprises of an equal number of step support units defining the stringers and a series of steps adapted to be mounted to said step support units, said step support units each comprising a main structural body adapted to support said steps thereon, a first mating structure extending substantially laterally from a first lateral side thereof and a second mating structure extending substantially laterally from an opposing lateral side thereof, within a same stringer said first mating structure of said units being adapted to be matingly coupled with an adjacent second mating structure of an adjacent unit such that said adjacent unit is vertically offset therefrom.
Still in accordance with the present invention, there is provided a modular stringer for a staircase, the stringer comprising at least two coupled free standing step support unite defining the stringer, said step support units each comprising at least one shaft extending vertically at least partially along a first lateral side thereof and at least one coupling arm extending substantially laterally and horizontally from an opposing lateral side thereof, said coupling arm of a first step support unit being adapted for accepting and solidly retaining said shaft of an adjacent step support unit therein such that said adjacent step support unit may be vertically offset therefrom.
Still in accordance with the present invention, there is provided a kit for erecting a curling staircase lined by an outside structure defining an outside curl of said staircase, the kit comprising a modular stringer comprised of at least two modular step support units defining the stringer, a set of corresponding wall mountable step support units and a set of steps adapted to be mounted on said step support units, said modular step support units each comprising at least one shaft extending vertically at least partially along a first lateral side thereof and at least one coupling arm extending substantially laterally and horizontally from an opposing lateral side thereof, said coupling arm of said modular step support units being adapted for accepting and solidly retaining said shaft of an adjacent modular support unit therein such that said adjacent modular support unit may be vertically offset therefrom.
Still in accordance with the present invention, there is provided a kit for erecting a staircase between two lining structures, the kit comprising at least two stringers adapted to be mounted to said lining structures and a series of steps adapted to be mounted to said stringers, each said step comprising a tread and a riser, the kit further comprising a plurality of step mounting brackets used to mount said treads and said risers to said stringers, wherein said treads and said risers are adapted to extend horizontally between said stringers and to be fastened thereto such that a mounted tread defines a substantially horizontal tread surface and a mounted riser defines a substantially vertical riser surface extending upwardly from an area proximal to a rear end of a lower mounted tread and an area proximal to a front end of an adjacently mounted higher tread, wherein a first flange of said step mounting brackets is adapted to be fastened within a recess provisioned therefor in a longitudinal face of longitudinal ends of both said treads and said risers and wherein a second flange of said step mounting brackets is adapted to be fastened to said stringers.
Still in accordance with the present invention, there is provided a method for erecting a self-standing staircase between an upper structure and a lower structure, the method comprising the steps of:
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- a. providing a set of step support units, a set of steps, two upper support Structures and two lower support structures, said step support units each comprising a first mating structure extending substantially laterally from a first lateral side thereof and a complementary mating structure extending substantially laterally from an opposing lateral side thereof;
- b. building two substantially similar stringers by matingly coupling said first mating structure of said step support units with said complementary mating structure of successive adjacent step support units in a same stringer;
- c. respectively coupling said upper support structures and said lower support structures to uppermost and lowermost step support units of each said stringers;
- d. respectively mounting said upper and lower support structures to the upper and lower structures, and
- e. mounting said steps on said step support units.
Still in accordance with the present invention, there is provided a method for erecting a self-standing curling staircase along a wall defining an outside curl of the staircase between an upper structure and a lower structure, the method comprising the steps of:
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- a. providing a set of modular step support units, a set of wall mountable step support units, a set of steps, said modular step support units each comprising at least one shaft extending vertically at least partially along a first lateral side thereof and at least one coupling arm extending substantially laterally and horizontally from an opposing lateral side thereof;
- b. building a curling stringer by coupling said shaft of said modular step support units with said coupling arm of successive adjacent modular step support units;
- c. securing said stringer between the upper and lower structures;
- d. mounting said wall mountable step support units to the wall such that once mounted, said wall mountable step support units operate cooperatively with said modular step support units; and
- e. mounting said steps on said step support units.
Still in accordance with the present invention, there is provided a method for erecting a staircase between two lining structures, the method comprising the steps of:
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- a. providing two risers each defined by successive horizontal tread bearing and vertical riser bearing surfaces, a set steps comprising a set of treads and a set of risers, a set of stop mounting brackets, a set of finishing modules and a set of finishing brackets;
- b. mounting said stringers to the lining structures;
- c. fastening a first flange of said step mounting brackets and a first flange of said finishing brackets within a recess provided therefor in longitudinal ends of said treads and said risers;
- d. successively mounting said treads and said risers by respectively fastening a second flange of said step mounting brackets to said tread and sold riser bearing surfaces; and
- e. inserting said finishing modules between each said step along the lining structures by sliding said finishing modules between said longitudinal ends and a second flange of said finishing brackets.
Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of illustrative embodiments thereof, given by way of example only with reference to the accompanying drawings.
Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration, illustrative embodiments thereof, and in which:
Referring to
Adding reference to
Referring now to
To fasten the two-step supports 20 together, a set of bolts (not seen) are fitted through the aligned circular and rectangular holes 32 and 34 respectively, and secured using a set of nuts solidly fastened thereto (also not seen). To enhance the solidity and strength of the combined structure, a third bolt, or again a nail or a screw, may be secured though the square hole 36 of the female flange 26 by piercing a matching hole 38 at the bottom of the male flange 24, thereby also securing the adjusted position of mated supports 20.
A person of ordinary skill in the art will understand that other fastening means may also be considered to fasten the step units together. For instance, the circular holes 32 could be threaded and the fastening bolts could be fastened therein to provide a secure juncture. Alternatively, the circular holes 32 could be replaced with bolts integrally coupled to the male flange 24 and extending outwardly therefrom to be guided through the oblong holes 34 of the female flange 26 and secured therein using a set of nuts. Additionally, an intermediary mating member could be inserted between each mating flange pair to enhance the coupling thereof. Further fastening and coupling means and techniques may also be considered without departing from the general scope and nature of the present disclosure.
Referring back to
Adding reference to
Referring now to
Once both stringers 18 are securely in place, thereby providing a solid framework for the staircase S, the various components of the steps, as well as any finishing components enhancing the aesthetic value of the staircase S may be coupled thereto. As will become apparent to a person of ordinary skill in the art, the staircase S may also be constructed progressively, laying every step in a successive or predefined order.
Referring now to
To mount the various staircase components, a series of Reshaped brackets 68 and J-shaped brackets 70 are first fitted to the treads 14 and risers 16. The brackets 68 and 70, which may be manufactured of a hard plastic, a metal, or any substantially rigid material, are used to fasten the treads 14 and risers 16 to the stringers 18 and provide means for coupling the wall covers 66 thereto.
With specific reference to
With specific reference to
Referring back to
Once the riser 16 is secured into places an L-shaped bracket 68T and two J-shaped brackets 70T are fastened to the side wall of the tread 14. The tread is then positioned on the stringer 18 such that the back face 92 of the tread 14 abuts on the front face 94 of the riser 16 and such that the bottom face 96 of the tread 14 rests on the top face 22 of support 201, The tread 14 is then fastened to the support 201 using the second flange 74 of the L-shaped bracket 68T extending sidewardly therefrom. The same procedure can then be repeated for every successive step 12. As for the uppermost riser 16U, the brackets 68 and 70 may be fastened directly in the upper floor structure U.
To accommodate various wall imperfections, the L-shaped brackets 68 provide a lateral adjustment range, thereby allowing the steps 12 to be adjusted accordingly between the stringers 18. As will be discussed further hereinbelow, the lateral adjustment range depends on the actual width of the modular supports 20 to which are fastened the brackets, Illustratively, the lateral adjustments may range between ¼ inch and ½ inch, though larger or smaller ranges may be considered by modifying the width of the supports 2a. Alternatively, the T-shaped brackets 68 could comprise an oblong hole 78 rather than a circular hole, thereby providing a similar feature.
Still referring to
Due to the adjustability of the riser heights, namely by adjusting the coupling of the step supports 20, the wall covers 66 may be correspondingly shifted, thereby producing an undesirable visual effect. To address this effect, a border or moulding 67 may be fitted on top of the wall covers 66. As illustrated in
Generally, the step supports 20 will allow a step 12 of standard width to be fastened thereto with a certain margin of flexibility, namely governed by the thickness of the stop supports 20 to which will be fastened the steps 12. Namely, as presented hereinabove, lateral adjustments ranging between a quarter (¼) and a half (½) inch are provided by the illustrated supports 20. By varying the thickness of the supports 20, smaller or greater ranges may be considered. Brackets 68 with oblong rather than circular holes 78 could also provide a similar advantage.
Consequently, adding reference to
Referring now to
To install these components, the boards 69 may first be glued to the supports 20. A Z-shaped bracket 115 is then nailed to the bottom inside face of the running board 71. The running board 71 is then fitted below the boards 69 by sliding the tongue 109 lining the bottom of the boards 69 into the groove 111 lining the top of the running board 71 and resting the Z-shaped bracket 115 against the wall W. A set of finishing nails 113 are used to secure the juncture between the boards 69 and the running board 71, and a bottom moulding 117 is nailed at an angle below the running board 71 to hide the space between same and the wall W and hide the Z-shaped bracket 115 therebehind.
As presented hereinabove with reference to
As will now be apparent to a person of ordinary skill in the art, other masking means may be employed to cover and hide the staircase hardware and wall imperfections without departing from the general scope and nature of the present embodiment. Furthermore, various fastening means, such as bolts, screws, nails and glue may be used alone or in combination to fasten the various components in the kit. In addition, the staircase S may also be fully constructed prior to installation, leaving only possibly a few aesthetic components to be installed once the staircase is put in, such as the wall covers 66 and mouldings 67.
In addition, various materials may be considered for the manufacture of the various staircase components. Namely, the treads 14, risers 16, covers 66 and mouldings 67 may each be manufactured of varying hardwoods, softwoods, composite materials and/or plastics and provide varying finishes. Since all the hardware is adequately hidden by these components, damage to the finished surfaces is avoided. Alternatively, unfinished materials may also be used for the subsequent painting or covering thereof.
Referring now to
The staircase S′ is illustratively comprised of a set of steps, as in 112, mounted on two lateral stringers, as in 114. The stringers 114, which extend obliquely from the bottom structure 108 to the upper structure 110 are comprised of individually adjusted modular step supports, as in 116 assembled to form the stringers 114. As will become apparent to a person of ordinary skill in the art, though the steps 112 of the alternative staircase S′ do not comprise risers per say, risers could just as well be included in the general construction of the staircase S′ without departing from the general scope and nature of the present embodiment.
Adding reference to
Referring now to
To fasten the two step supports 116 together, a set of bolts 132 are fitted through the aligned circular and rectangular holes 128 and 130 respectively, and secured using a set of nuts 134 solidly fastened thereto. For a smoother finish, the fastening holes 128 and 130 may be recessed such that the belts and nuts do not extrude significantly from the plane of the supports 116. To enhance the solidity and strength of the combined structure, a third bolt may be secured though the square hole 138 of the female flange 124 by piercing a matching hole 138 at the bottom of the male flange 122.
Referring back to
Adding reference to
Referring now to
Once both stringers 114 are securely in place thereby providing a solid framework for the staircase S′, the various components of the steps, as well as any finishing components enhancing the aesthetic value of the staircase S′ may be coupled thereto. As will become apparent to a person of ordinary skill in the art, the staircase S′ may also be fully constructed prior to installation without departing from the general scope and nature of the present disclosure.
Referring now to
Still referring to
A person of ordinary skill in the art will understand that other mounting and fastening means may be employed without extending the general scope and nature of the illustrative embodiment. For example, alternative brackets may be used to provide lateral adjustability to the steps 112. Furthermore, the use of additional brackets may increase the strength and stability of the steps 112. Finally, the steps 112 may be manufactured of any solid material such as hard plastics, wood, metal and steal. The steps may also be covered with paint or carpet, or again present a rugged or textured surface for increased grip. Finally a set of risers may also be coupled to the staircase S′ using an additional set of brackets 170 fitted to the step supports 116, or other such fastening means.
Additionally, still referring to
Referring now to
Various fastening means may be utilised to mount the aesthetic sheeting 182 to the staircase S′. Namely, a set of hardware clips and brackets may be fastened to the step supports 116 to hold the sheeting thereon. Alternatively, the sheeting 182 may also be glued onto the step supports 116.
Referring now to
Adding reference to
Adding reference to
Still referring to
Referring now to
Adding reference now to
Adding reference now to
From the above illustrations, it will now be apparent to a person of ordinary skill in the art that various step lengths, heights, rotations and consequently, various staircase pitches may be obtained with these adjustable modular step supports 192. Furthermore, though the illustrated
Referring hack to
Consequently, the steps may be constructed on the wall-mounted tread and riser supports 190 and the modular step supports 192. Risers will be secured to the lateral faces 196 of the supports 192 and correspondingly to the riser supports. As for treads 186, they will be secured to the top faces 195 of the supports 192 and the wall-mounted supports 190. To mount the risers 188 and treads 186, various clips and brackets, as used in the construction of staircases S and S′, may also be used to provide versatility in the construction of staircase S″. For instance, by using L-shaped brackets in this alternative embodiment, the steps may also be adjusted laterally to accommodate various imperfections in the staircase materials or structures on which the staircase S″ is mounted. Furthermore, by incorporating J-shaped brackets, or other such brackets to the risers 188 and treads 186, or again directly to the modular step supports 192, various ornamental and aesthetic features may be added to the staircase S″, namely borders, mouldings and other such elements.
Alternatively, as illustrated for staircase S′, various ornamental sheetings or covers may be fastened of glued to the supports, thereby also providing a finished look. Additionally, a railing may also be added to the staircase S″ by the coupling thereof to the modular brackets 192, or again to the treads 186 or risers 188 directly.
As will be apparent to a person of ordinary skill In the art, the staircase S″ is completely customizable and mountable on site with a minimal amount of tools. For instance, even if the staircase is not designed in advance, the modular supports 192 may be adjusted on site to accommodate the specific configuration of the stairwell, and the wall-mounted supports, which may include i-shaped brackets as in 190, a one-piece or a modular stringer, or other such mounting means, may be secured to the wall W″ to correspond therewith. The treads 186 and risers 188 may then be cut to size on site. Alternatively, the staircase S″ will be designed in advance, and parts may be brought in for a direct fitting in the stairwell. Also, the staircase S″ may be fully manufactured prior to Installation. Again, finishing touches such as wall covers and mouldings may be added to cover the hardware and spiral stringer of the staircase S″ using various clip and bracket systems such as discussed hereinabove with reference to staircase S and the Figures related thereto. Furthermore, various building materials such as hard and soft woods, finished or unfinished, as well as covered and uncovered metals and plastics may all be considered to construct the staircase S″.
As illustrated in the above Figures, adjustable modular stringer and step support kits may be used to construct staircases ranging from linear industrial and residential staircases, to spiralling and customized staircases. Each configuration providing options on adjustability and finish.
It is to be understood that the invention is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The invention is capable of other embodiments and of being practised in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation. Hence, although the present invention has been described hereinabove by way of illustrative embodiments thereof, it can be modified, without departing from the spirit, scope and nature of the subject invention as defined in the appended claims.
Claims
1. A modular stringer for a staircase, the stringer comprising at least two matingly coupled step support units defining the stringer, said step support units each comprising a main structural body, a first mating structure extending substantially laterally from a first lateral side thereof and a second mating structure extending substantially laterally from an opposing lateral side thereof, said first mating structure of said step support unit being adapted to be matingly coupled with an adjacent second mating structure of an adjacent step support unit such that said adjacent unit is vertically offset therefrom.
2. The modular stringer as claimed in claim 1, said first mating structure comprising a male mating structure and said second mating structure comprising a female mating structure.
3. The modular stringer as claimed in claim 1, said first mating structure comprising at least one fastener integrally coupled thereto and said second adjacent mating structure comprising a corresponding fastening hole for each of said at least one fastener, said fastener engaging said second adjacent mating structure through said corresponding fastening hole thereby fastening said mating structures together.
4. The modular stringer as claimed in claim 3, wherein said fastener is a threaded bolt, said bolt being secured within said corresponding hole by a nut.
5. The modular stringer as claimed in claim 3, wherein said fastener comprises a transversal hole at a distal tip thereof, said fastener being secured within said corresponding hole by a securing pin fitted through said transversal hole.
6. The modular stringer as claimed in claim 1, said first mating structure and said adjacent second mating structure comprising at least one pair of corresponding fastening holes, said pair for fastening said first and said adjacent second structures together using at least one fastener engaged through said pair.
7. The modular stringer as claimed in claim 6 wherein at least one of said corresponding fastening holes is threaded and wherein said fastener is a bolt threadingly engaged therein for fastening said first and said adjacent second mating structures.
8. The modular stringer as claimed in claim 6 wherein said fastener is a bolt secured within said pair by a respective nut.
9. The modular stringer as claimed in claim 6 wherein said first and said second mating structures define vertically oriented mating elements and wherein at least one of said corresponding fastening holes is a vertically elongated hole such that said first mating structure is vertically adjustably coupled and fastened to said adjacent second mating structure.
10. The modular stringer as claimed in claim 9, wherein once said first and said adjacent second mating structures are fastened together, an additional pair of corresponding fastening holes is created to further secure said fastening of said mating structures using an additional fastener.
11. The modular stringer as claimed in claim 10 wherein one of said additional pair of corresponding fastening holes is a predefined fastening hole.
12. The modular stringer as claimed in claim 1, the modular stringer further comprising at least one intermediary mating member for each two step support units, said mating intermediary member being adapted for matingly fitting between said first mating structure and said adjacent second mating structure for the coupling thereof.
13. The modular stringer as claimed in claim 1, the stringer further comprising an upper support unit and a lower support unit, said upper support unit comprising a mating structure for a mated coupling thereof with one of said first or said second mating structure of an uppermost step support unit of the stringer and a means for supporting the stringer from a top end thereof, said lower support unit comprising a mating structure for a mated coupling thereof with one of said first or said second mating structure of a lowermost step support unit of the stringer and a means for supporting the stringer from a bottom end thereof.
14. (canceled)
15. The modular stringer as claimed in claim 13, wherein said structural body of said step support units is adapted to be fastened to a support structure lining said stringer and extending substantially parallel to said structural body.
16. (canceled)
17. A step support unit to be matingly coupled with at least one structurally similar adjacent step support unit such that said adjacent unit is vertically offset therefrom, the unit for the construction of a modular stringer for a staircase, the step support unit comprising a main structural body, a first mating structure extending substantially laterally from a first lateral side thereof and a second mating structure extending substantially laterally from an opposing lateral side thereof, said first structure comprising at least one mating element and said second structure comprising at least one complementary mating element complementary to said mating element of said first structure and vertically offset therefrom.
18. The step support unit as claimed in claim 17, wherein said mating element of said first structure defines same as a male mating structure and said complementary mating element of said second structure defines same as a female mating structure.
19. A kit for erecting a staircase between an upper and a lower structure, the kit comprising at least two modular stringers each comprised of an equal number of step support units defining the stringers and a series of steps adapted to be mounted to said step support units, said step support units each comprising a main structural body adapted to support said steps thereon, a first mating structure extending substantially laterally from a first lateral side thereof and a second mating structure extending substantially laterally from an opposing lateral side thereof, within a same stringer said first mating structure of said units being adapted to be matingly coupled with an adjacent second mating structure of an adjacent unit such that said adjacent unit is vertically offset therefrom.
20. (canceled)
21. (canceled)
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24. The kit as claimed in claim 19, said first mating structure and said adjacent second mating structure of said same stringer comprising at least one pair of corresponding fastening holes, said pair for fastening said first and said adjacent second mating structures of said same stringer together using at least one fastener engaged through said pair.
25. The kit as claimed in claim 24 wherein said first and said second mating structures define vertically oriented mating elements and wherein at least one of said corresponding fastening holes of each said pairs is a vertically elongated hole such that said first mating structure is vertically adjustably coupled and fastened to said adjacent second mating structure of said same stringer.
26. The kit as claimed in claim 25, wherein a relative height between successive steps in the staircase can be adjusted by vertically adjusting a relative height between corresponding successive step support units in said stringers.
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Type: Application
Filed: Mar 21, 2005
Publication Date: Sep 25, 2008
Applicant: (Cowansville (Quebec))
Inventor: Couture Raymond (Cowansville)
Application Number: 10/593,472
International Classification: E04F 11/025 (20060101);