PRECISION BUILT STAIRCASE
A precision built staircase kit is disclosed. The kit includes a plurality of stringers that include a structural stringer, a decorative stringer and a winder stringer that are cut by a high precision machine, a skirt board, a plurality of risers with a pair of ends and a plurality of squares. The staircase also includes a plurality of winder treads wherein the stringers, the skirt board, the risers and the treads form a plurality of stairs, a recessed tread end cap, one or more cover joints and corner joints to cover a plurality of cuts, a decorative panel disposed on the back of staircase after the stairs are formed and a packaging box that stores a plurality of unassembled staircase components and that forms a cabinet or a closet when empty. The staircase may be assembled from a kit with a method of assembling.
The present application is a Continuation-In-Part and claims the benefit to U.S. Non-Provisional application Ser. No. 13/817,398 filed on Jun. 5, 2013, U.S. Non-Provisional application Ser. No. 13/817,398 filed on Jun. 5, 2013 claims priority to U.S. Provisional Application 61/374,571 filed on Aug. 17, 2010, the entire of all disclosures are incorporated by reference herein.
TECHNICAL FIELD & BACKGROUNDStaircases have always been a hidden safety concern. Many times staircases have been assembled or constructed improperly and are unsafe. Imprecise measurements and cutting of staircase parts and components often result in unsafe steps and other staircase components that may result in people falling or tripping on the staircase as well.
The present invention relates to a staircase. More specifically, the present invention relates to a precision built staircase.
It is therefore an object of the present invention to provide a precision built staircase that is quicker and easier to assemble, has a longer-lasting aesthetically pleasing appearance and utilizes more precise pre-manufactured profiled structural stringers and pre-profiled decorative stringers than current staircases.
It is another object of the present invention to provide a precision built staircase with an added standard skirt board and a plurality of accessories that may be assembled in a few minutes that may be in compliance with various building codes and standards.
It is also an object of the present invention to provide a precision built staircase with a plurality of components with a plurality of aesthetic embodiments that may be manufactured with precision machinery such as a computer numerical control or a CNC router machine. The stair components to be profiled from a panel may be preferably routed face-to-face reversed (top-bottom, bottom-top) for raw material economy in the range of 26% to 38% for a first set of structural stringers and eliminate the need to make another set of structural stringers when the decorative final staircase may be installed.
It is an object of the present invention to provide a precision built staircase that ensures consistent dimensional productivity and installation at the right position with a plurality of winder's treads and risers set by utilizing a starter winder tread plank and a pre-profiled nose angled to a plurality of winder's treads that may be also easy to fix, well-aligned at the front surfacing and angled at approximately 90 degrees to the front of the starter winder tread plank and are quickly installable into a starter winder tread plank slot for a better final result.
It is another object of the present invention to provide a precision built staircase that allows easy and rapid assembling and attachment of the staircase components that includes a plurality of pre-drilled apertures and a plurality of standard brackets that may be glued together without any excess overflow of glue to a plurality of treads, risers and stringers.
It is also another object of the present invention to provide a plurality of standard skirt boards that may be temporarily or permanently utilized at a plurality of predetermined heights that are attached securely with one or more covers and one or more corner joints.
It is an object of the present invention to provide a precision built staircase with a plurality of components that may be easily sold and kept in stock across distributors, retailers, agents, installers, finishers and do-it-yourself suppliers on the market.
It is another object of the present invention to provide a plurality of precision built staircase components that may be easily stocked in a weather regulated warehouse or a store, that includes structural stringers, decorative stringers, skirt boards and other stair components that will not warp, curve, crack or split by utilizing kiln dried, engineered composite materials and/or other materials.
It is another object of the present invention to provide a precision built staircase in a kit form in a pre-assembled box that may be utilized as a cabinet, a closet or an outside shell that may be also available in a pre-finished or a non-finished form.
It is another object of the present invention to provide a precision built staircase that may utilize a plurality of different sizes, types, lengths, gages, with or without headed nails and screws.
It is another object of the present invention to provide a precision built staircase that is made of composite, hardwood, softwood, aluminum, steel, concrete, marble, granite, rough or prefinished materials, or other suitable engineered materials pre-assembled or non-pre-assembled.
It is another object of the present invention to provide a precision built staircase that may utilize a wide variety of glue types.
It is another object of the present invention to provide a precision built staircase and related components that may be manufactured in any desired shape, size, and/or dimensions.
The present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawings in which like references denote similar elements, and in which:
Various aspects of the illustrative embodiments will be described using terms commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. However, it will be apparent to those skilled in the art that the present invention may be practiced with only some of the described aspects. For purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the illustrative embodiments. However, it will be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well-known features are omitted or simplified in order not to obscure the illustrative embodiments.
Various operations will be described as multiple discrete operations, in turn, in a manner that is most helpful in understanding the present invention. However, the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations need not be performed in the order of presentation.
The phrase “in one embodiment” is used repeatedly. The phrase generally does not refer to the same embodiment, however, it may. The terms “comprising”, “having” and “including” are synonymous, unless the context dictates otherwise.
In accordance with these objects which will be discussed in detail below, the present invention provides a complete line of modified stair components and, when assembled together with a plurality of accessories and an installation stair kit reduce installation time, achieve a higher percentage savings of raw material, manufacturing time, and installation time with high precision.
The staircase 500 may relate to modifications and ameliorations that make the staircase 500 relatively easier to install and may be typically more economical to manufacture, saving manufacturing time and raw materials than traditional staircases and reduce in the range of 30% to 70% of the installation time due to the high precision of machinery (e.g., CNC router) utilized to produce many of the staircase components. When the staircase 500 may be assembled, the final result will be a better temporary fit or permanent fit. The staircase 500 may permit re-use of the structural stringers 3 installed at the beginning of construction and may only replace a rough tread 18 and a riser 17 initially and be temporarily installed by a plurality of chosen decorative treads 1, 10, 10A, 10B, 10C and risers 200, a decorative stringer 4, a pre-profiled skirt board 5 and any other desired components, pre-finished or to be finished on a job site.
Staircases currently available on the market may be mostly assembled on a job site and to save installation time, few distributors offer them pre-assembled which may also be prefinished. When assembled on a job site, most of the time, stringers 3 may be cut manually with a skill saw approximately 2 inches×2 inches×12 inches which may be where precision discrepancies occur. When the staircases may be assembled at a manufacturing site, they do not necessarily have the high precision machines (CNC router) to perfectly cut the stringers 3, 4 and other high precision component's cut to the staircase 500 to size, if necessary. Typically it's very difficult to determine in advance the precision squaring and leveling of the walls, floors and ceiling formed approximately 95% of the time in a new building or a remodeled job site, resulting that some percentage of components fabricated or adjusted onsite must be reprocessed, resulting in a costly operation.
Installation of the staircase 500 may be considered by professional building contractors to be complicated work. The staircase 500 may be imperative to introduce into a large market, products that may be installed in less time and with more efficiency and precision than traditional staircases. Structural stringers 3 may be a significant part of substantial saving in manufacturing, raw material, installation time and an attractive final long lasting aesthetic appearance. Regarding the stringers 3, 4 and pre-profiled skirt board 5, the manufacturing's precision and relative rapid execution offer distributors, retailers and others a reasonable price and better compliance of building codes. Structural stringers 3, decorative stringers 4, a pre-profiled skirt board 5 and a plurality of winder's treads (
The one or more tread's end caps 11, 12, 13 may be added at one or both sides of treads 1, 10, 10A, 10B, 10C and formed recesses made at a depth of the typical length of overpass of the decorative stringer 4 (open decorative stringer) at approximately ±50% of thickness of tread and at approximately 100% or less of the width of treads (
The pre-profiled skirt board 5 may be installed quickly without any scratches on the treads 1, 10, 10A, 10B, 10C or the risers 17, 200 such as a plurality of pre-finished treads or a plurality of pre-finished risers utilizing a plastic tape 6, with a resistant glue 7 disposed on one side of the plastic tape 6. The pre-profiled skirt board 5 may be laid down over the plastic tape 6 preinstalled at a wall side over the treads 10, 10A, 10B, 10C and the risers 17, 200. The basic skirt board (
The cover joint 18a, 18b, 18c and the corner joints (
When the rough and/or decorative staircase components may be ready to be installed, a reversible square 15 or bar (not shown) could be secured by gluing, nailing or screwing to the inside structural stringer 3 at the back of staircase 500. The square 15 or bar (not shown) underneath the rough tread 18 may be set in place and pushed to the back of the riser 17 that may be already secured in place. It may be significant to install at least two previously described auto adhesive resilient material or spongy material (
With the height of risers 47A and tread's runs 43A being precise, further ameliorations allow for an easier and quicker installation. After face-to-face manufacturing, the risers 47A and tread's runs 43A may be approximately identical. Tread run 43 is equivalent to 43A, nose profile 44 is equivalent to 44A, riser height 47 is equivalent to 47A and the top of the staircase skirt board 42 is equivalent to 42A. Most of the staircase 500 may be made with a reversible pair face to face like process. Nose profiles 44 and 44A may be profiled at any desired shape and dimensions.
Some pre-shaped inside square cover (
When utilized as a pre-cut skirt board, the pair of square pre-cut stringers 601 may be fixed directly over the stringer, treads and risers that may be installed properly against the pre-cut skirt board and if some imperfections occur then tread rims (
The pre-shaped outside square cover or end cap (
The pre-shaped outside square cover (
The pre-shaped inside square cover (
The back of staircase 500 has to be finished and frequently a professional contractor installer or painter may be required to return several times to completely finalize the staircase construction, which may be costly. One way to eliminate this may be to supply standard backing panels to be adjusted to the back of the staircase to be typically equally cut at the jobsite at each side, to be properly fit, pre-finished and fabricated from any suitable material available. The backing panel of the staircase may be pre-finished or non-prefinished, plain or with any suitable types of printed, pressure printed, molded designs, grooved or with any suitable designs, textural finish or composition of products adaptable to the back of staircase stringers 3 or 4. Many different types of molding shapes or designs may be added to all joints and/or walls, floors or ceilings adjacent to the staircase 500. If the stairs, backing panel and moldings may be pre-finished, there may be no need to have other professionals come back to finalize the construction of the staircase, resulting in a substantial savings of time and money with a more convenient decorative final result. The decorative backing panel of the staircase may be installed with a plurality of nails or a plurality of screws with or without glue with preferably some backing cross-member installed between the stringers when necessary and desired sound padding may be added between standard backing panel and back of treads and risers. Any molding (
A standard holder bar will come at a plurality of predetermined lengths and typically has the same dimensions as the top of the longer side of the square (
After completion of these operations, all rough treads (
When an end-user desires a permanent and solid installation, glue may be typically applied to the structural stringers (
Some others modifications to risers 200 and treads 10 will attach them at the right position quickly, precisely and tight fit together temporarily and/or permanently (with or without glue) to underneath the front of tread 116. One of these may be, at least one aperture 210 located at the approximate middle of the top riser length and plus or minus half-thickness of the riser to insert a dowel 205 or preferably a spring 206 plus a dowel 205 in wood or in other material to the bloc riser at the desired position when the dowel 205 may be engage in a slot (
Top of risers 207A and bottom of risers 202A may be nailed or screwed to riser height (
There may be also a tread groove (
Any of the one or more grooves provide a strong, permanent and tight attachment of any adjacent components when the components may be made of wholly or partly engineered products, such as OSB, particleboard, fiberboard, plywood, LVL, LSL, softwood and other materials that may easily possibly break, split or allow for a screw or nail to be easily torn-off or removed.
Starter winder tread plank 101 assures the installation of winder's treads 1,2,3 to firmly and accurately align each other in a plurality of predetermined single or double recessed slots 1A,2A,3A at a predetermined precise riser height desired and to tightly attach winder's risers 1B,2B,3B,4B at right angles to the adjacent to wall starter winder tread plank 101 and winder's treads 1,2,3 together.
Decorative starter plank jacket 100 may be added any time after treads and risers may be installed over the rough starter plank 99 and holder of starter plank. To build a staircase 500 on-site will save from 4 to 6 hours of installation time in contrast to a traditional staircase and to build on site a staircase 500 with a set of 3 winder's treads and risers, the saving time will be up to 9 hours in contrast to a traditional staircase. This large time savings will be appreciated by professional building contractors and do-it-yourself customers who wish to install their own staircase.
Decorative starter plank jacket 100 may be added any time after treads and risers may be installed over the rough starter plank 99 and holder of starter plank. To build a staircase 500 on-site will save from 4 to 6 hours of installation time in contrast to a traditional staircase and to build-on site a staircase 500 with a set of three winder's treads and risers, the saving time will be up to nine hours in contrast to a traditional staircase. This large time savings will be appreciated by professional building contractors and do-it-yourself customers who wish to install their own staircase.
Packing box 2400 may be provided to transport any staircase components that need to be protected when carried to the job site. Some components may be long such as stringers 3, 4 and the basic skirt board 5, 2631 and may be also fragile to carry. More specifically when prefinished, the packaging box 2400 should be solid and very protective and typically may be very costly. The packing box may also have a second use as a cabinet and/or closet with or without a door or a cover 2430 that may also be split into two or more sections 2410 and 2420 that may also be usable as furniture (e.g. a cabinet for tools and accessories or a shoes cabinet open shell) or any other desired suitable utilities or applications, pre-finished or non-pre-finished. The packing box may potentially save money, prevent environmental waste, as well as protect staircase components to be delivered and serve as a strong marketing tool for a manufacturer, or any intervenient in distribution and sale of staircases and or other domains. The dual purpose packing box may be adapted to any type of suitable products to be carried needing suitable appropriated protection. The packing box may be made of any suitable type of material, at any suitable desired dimensions, engineered design, or other needed specification. Different kits of shells, doors and accessories associated with the packing box 2400 will be available on request and may be customized with specified specifications as well.
The back of the staircase 500 may be attached between the first wall 2510 and the second wall 2520 and behind a third wall 2530. A skirt board starter joint 2542 attaches the back of the staircase 500 with the third wall 2530 typically at each corner. There may be also a corresponding cap 2540 disposed on each of the skirt board starter joints 2542 to protect the skirt board starter joints 2542. A winder starter plank 2550 attaches the back of the staircase 500 to the first wall 2510. A cap 2552 may also be disposed on the winder starter plank 2550 to protect the winder starter plank 2550 and skirt board's cuts. A middle skirt board joint 2560 attaches the back of the staircase 500 to the second wall 2520. A cap 2562 may be disposed on the middle skirt board joint 2560 to protect or cover the middle skirt board joint 2560. An outside skirt board corner joint 2570 also attaches the back of the staircase 500 to the second wall 2520. A cap 2570 may be disposed on the outside skirt board corner joint 2580 to protect the outside skirt board corner joint 2580. A tread rim extender tread 2590 additionally attaches the first wall 2510 to the back of the staircase 500. A tread rim 2595 may be disposed to slide underneath the tread rim extender tread 2590 to further attach the back of the staircase 500 to the first wall 2510. A reversible molding 2575 also attaches the back of the staircase 500 to the first wall 2510. A skirt board ender joint 2585 may be disposed underneath the reversible molding 2575 to further attach the back of the staircase 500 to the first wall 2510. A cap 2587 may be disposed on the skirt board ender joint 2585 to protect the skirt board ender joint 2585 and the basic shirt board (
The staircase 500 includes the reversible molding 2575 or 560 which may be disposed on top or bottom of the staircase 500. There may be also a cap 2610 on the top of starter corner joint 2540 of the staircase 500. The skirt board inside corner joint 2540 may be underneath the cap 2610. A tread rim block 2620 may be disposed underneath the skirt board start joint 2540. A tread rim extender 2630 may be vertically or horizontally attached to each vertical portion of a basic skirt board 2631 of each height of the staircase 500. The tread rim extender 2630 may be attached to the vertical portion basic skirt board 2631 with preferably at least one pinned nail. The tread rim 2595 may be then provided on the distal end 2650 of the horizontal portion 2652 of each step. The round cover 15C secures the vertical portion 2642 and the horizontal portion 2644 together and the screws 209 assemble firmly top riser to underneath tread nose side and same for bottom front riser to back of tread. The overlap angled molding 560 has a pair of ends 562 with an L-shape flat flange 2660 provided on the ends 562 of the overlap angled molding 560. The skirt board ender joint 2585 and cap 2587 may be provided at the bottom of the staircase 500.
The packing box 2400 will permit the delivery of longer components such as full length skirt boards, stringers and full length molding 560 and 2575 without anxiety regarding the components being broken or damaged while being transported.
The structural stringer 3 has a plurality of grooves 2710 disposed on top of the structural stringer 3. The grooves 2710 may be typically convex grooves 2712 but may be any suitable shape. The grooves 2712 permit glue to overflow and spill on either side of the grooves 2710 and permit a better and larger grid surface, while also providing a better hold and attachment at the right level. There may be one or more taper apertures 2720 provided as well. This reversible stringer-tread support 2700 sit perfectly in grooves 2710 of structural stringer 3 and eliminate the need to use any square 15 and (
The standard stringer tread support 2700 may also be reversible. A plurality of grooves 2712 found on structural stringer 3 permit the glue to overflow and spill on either side of the grooves and permit a better and larger grid surface while also providing a better hold and attachment.
Typically the grooves may be disposed around the sides of the stringer that may be cut with a plurality of grooves 2710 to lock down, align and set the reversible standard stringer tread support 2700 quickly at a desired height and level without the need to add 15A spongy material like the one utilized on top of square (
The screw 209 includes a threaded portion 2810, a screw head 2820 and a non-threaded portion 2830. The threaded portion 2810 may be disposed on a rear half 2802 with a distal end 2803 of the screw 209. The screw head 2820 may be disposed on a proximal end 2804 of the screw 209. The screw head 2820 may be a Phillips head shape 2822 or any other suitable shape of the screw head or combined example (Phillips and Square #3). The non-threaded portion 2830 may be disposed on a front half 2806 of the attachment screw 209 and accommodates a thickness of any tread. There may be also a self-drill end 2840 disposed on the end of the distal end 2803. Right now on the market, there may be no screw available for this application that may be more then steel gage number 9. Steel gage number 10 or higher should be utilized to firmly assemble a structural staircase.
While the present invention has been related in terms of the foregoing embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described. The present invention may be practiced with modification and alteration within the spirit and scope of the appended claims. Thus, the description is to be regarded as illustrative instead of restrictive on the present invention.
Claims
1. A precision built staircase kit for a precision built staircase, comprising:
- a plurality of stringers having a pre-profiled structural stringer with a horizontal, a vertical or an angled outside radius, a square or an inside radius, the stringers comprising: one or more risers; one or more treads; a set of winder stringers with an outside radius or a square; a winder tread plank; a pre-profiled skirt board or a pre-profiled standard board; a decorative horizontal stringer or a decorative vertical stringer or a decorative angled stringer with an outside radius or a square or a decorative inside stringer, the decorative stringer is pre-cut at 45 degrees or more at one or more riser heights levels; a plurality of squares, a plurality of bars or a plurality of reversible stringer supports with a horizontal top; a plurality of winder treads wherein the stringers, the treads, the risers, the winder skirt board, the starter winder treads plank, the winder risers and the winder treads with a 90 degrees perpendicularly short flat nose fit in the starter winder tread and a rim tread adapted to a nose shape, one or more slider extenders and a reversible molding to form a plurality of stairs; a recessed tread and end cap for an outside radius or a square cut and the inside radius; a pre-shaped outside square cover; an angled square cover; a pre-shaped inside radius cover; one or more cover joints and one or more corner joints to cover a plurality of skirt board cuts; a decorative panel disposed on a back of the staircase after the stairs are formed; a packaging box storing a plurality of unassembled staircase components that forms an open shell, a cabinet or a closet when empty; a reversible stringer support; a tread rim, one or more slider extenders and a reversible molding; a plurality of tread rim blocs; a plurality of L-shape flat flanges; a plurality of screws selected from the group consisting of a plurality of round head screw, a plurality of type 17 screw, a plurality of tempered screw or a plurality of #11 screw and higher, the screws are painted different colors in regard to the screw length; an installation kit to assemble the staircase components including all necessary screws to complete the installation of the staircase and to facilitate assembly of the staircase; and a reversible support, a winder starter winder treads plank, a tread rim, a tread rim extender tread, an outside skirt board corner joint, a skirt board starter joint, a skirt board ender joint, a middle skirt board joint, a reversible stringer-tread support and a plurality of corresponding caps to accommodate installing the staircase with a plurality of attachment screws having a threaded portion with a distal end with a self-drill end and a non-threaded portion to accommodate a thickness of the tread.
2. The staircase kit according to claim 1, wherein the staircase components are profiled reversed face to face from top to bottom or from bottom to top from a panel with a CNC router machine.
3. The stair kit according to claim 2, wherein the stringers and skirt boards are profiled reverse face to face from top to bottom or from bottom to top, from the panel with the CNC router machine around the staircase components in one pass and with or without one or more grooves.
4. The staircase kit according to claim 2, wherein the CNC router machine profiles most of the staircase components from a reverse face to face panel.
5. The staircase kit according to claim 2, wherein the CNC router machine is reverse face-to face for raw material economy in the range of 26% to 38% for a first set of structural stringers and eliminates the need to make another set of structural stringers when the staircase is installed.
6. The staircase kit according to claim 1, wherein the precision built staircase is assembled in a few hours that is in compliance with various building codes and standards.
7. The staircase kit according to claim 1, wherein the horizontal top square or bar accommodates one or more disposed auto-adhesive spacer pieces with one or more reversed tapered holes drilled from top of the horizontal top square or bar tread.
8. The staircase kit according to claim 7, wherein the spacer pieces are made of resilient or spongy material of any dimension and shape.
9. The staircase kit according to claim 1, wherein the reversible tread support is shaped with a tong overlapping at a longest top horizontal side, the reversible tread support having at least one reversed tapered hole drilled from top of said tread support.
10. The staircase kit according to claim 1, wherein the risers have one or more angled holes, pre-drilled and coupled directly underneath of the bottom back of the nose tread.
11. The staircase kit according to claim 1, wherein the risers are angled, pre-drilled and coupled directly underneath of the bottom back of the nose tread with at least one or more grooves at top.
12. The staircase kit according to claim 1, wherein the risers are coupled directly underneath of the bottom back of the nose tread with at least one or more grooves at top.
13. The staircase kit according to claim 1, wherein the risers have one or more lines to identify where to couple the bottom riser to the rear of the tread at the lowest line after cut from the bottom of the height of the riser.
14. The staircase kit according to claim 1, wherein the risers have one or more grooves at the front bottom for a fit and to minimize glue overflow.
15. The staircase kit according to claim 1, wherein the risers are precut at each end of the risers at a 45 degree angle or more.
16. The staircase kit according to claim 1, wherein the regular and recessed treads have one or more grooves at the rear of the tread.
17. The staircase kit according to claim 1, wherein the radius treads has a radius at the bottom rear of the tread.
18. The staircase kit according to claim 17, wherein the radius treads have the radius at the bottom rear of the tread with one or more grooves.
19. The staircase kit according to claim 1, wherein the regular treads have one or more grooves at the rear of the tread.
20. The staircase kit according to claim 1, wherein the radius or recessed treads have a radius at a bottom rear of the treads.
21. The staircase kit according to claim 1, wherein the radius or recessed treads have a radius at a bottom rear of the tread with one or more grooves.
22. The staircase kit according to claim 1, wherein the radius, the regular or the recessed treads have a slot at a bottom front of the tread with or without grooves, the treads receive a dowel emerging from a top of the riser.
23. The staircase kit according to claim 1, wherein the installation kit includes a plurality of screws to assemble all of the staircase components.
24. The staircase kit according to claim 1, wherein the staircase components are made of material selected from the group consisting of composite material, hardwood, softwood, aluminum, steel, concrete, marble, granite, laminated material, plywood, LVL, LSL, engineered material, kiln-dried material, rough material or prefinished material.
25. The staircase kit according to claim 24, wherein the staircase components are assembled in a few minutes and are in compliance with one or more building codes and standards.
26. The staircase kit according to claim 1, further comprising a packaging box that stores a plurality of unassembled staircase components and that forms an open shell, a cabinet or a closet when empty.
27. The staircase kit according to claim 1, wherein a plurality of pre-drilled apertures and a plurality of grooves minimize any excess overflow of glue to the treads, the risers and the stringers when assembled together.
28. The staircase kit according to claim 1, wherein a plurality of skirt boards that are temporarily or permanently utilized at a plurality of predetermined heights are attached securely with one or more covers and one or more corner joints and are covered with moldings profiled at 91 degrees or more from a back of any skirt boards.
29. The staircase kit according to claim 1, wherein a plurality of decorative stringers that are temporarily or permanently utilized at a plurality of predetermined heights are attached securely with one or more covers and one or more corner joints and are covered with moldings profiled at 91 degrees or more from a back of any of the decorative stringers.
30. The staircase kit according to claim 1, wherein a plurality of tread rims, a plurality of slider extenders and a plurality of reversible moldings are utilized to hide one or more nails or one or more screws used to couple the treads and the risers to the stringers.
31. The staircase kit according to claim 1, wherein the structural stringers, the decorative stringers, the skirt boards, the treads and the risers are made of kiln dried material, engineered material or composite material that will minimize warp, curve, crack or split.
32. The staircase kit according to claim 1, wherein the precision built staircase components are sold and kept in stock across a plurality of distributors, a plurality of retailers, a plurality of agents, a plurality of installers, a plurality of pre-assemblers, a plurality of finishers and a plurality of do-it-yourself suppliers on the market.
33. A method for assembling a precision built staircase kit, comprising the steps of:
- acquiring a plurality of staircase components;
- preparing a plurality of precision built staircase components from the staircase components with a piece of precision machinery;
- transporting the precision built staircase components to a jobsite; and
- assembling from top to bottom, the precision built staircase components on the jobsite to form the precision built staircase.
34. The method according to claim 33, wherein one or more skirt boards and one or more winder skirt boards are attached in a few minutes to a wall.
35. The method according to claim 33, wherein the precision machinery is a CNC router machine.
36. The method according to claim 35, wherein the CNC router machine reversed face-to face from top to bottom and from bottom to top for raw material economy in the range of 26% to 38% for a first set of structural stringers and eliminate the need to make another set of structural stringers when the staircase is installed.
37. The method according to claim 33, wherein decorative stringers and skirt boards are profiled with a precision machinery like the CNC router machine and installed in one or more length sections.
38. The method according to claim 37, wherein the structural stringers, the decorative stringers and the skirt boards are made of kiln dried material or engineered or composite materials and will minimize warp, curve, crack or split.
39. The method according to claim 33, wherein a plurality of skirt boards that are temporarily or permanently utilized at a plurality of predetermined heights are attached securely with one or more covers and one or more corner joints, the skirt boards are coupled at any usual degrees to the tread rims, the extenders and the reversible moldings.
40. The method according to claim 33, wherein the precision built staircase components are sold as individual components or in a staircase kit and kept in stock across a plurality of distributors, a plurality of retailers, a plurality of agents, a plurality of installers, a plurality of pre-assemblers, a plurality of finishers and a plurality of do-it-yourself suppliers on the market.
Type: Application
Filed: Nov 27, 2014
Publication Date: Mar 26, 2015
Inventors: Réjean Plante (Drummondville), Louise CUSSON (Drummondville)
Application Number: 14/555,666
International Classification: E04F 11/02 (20060101); E04F 11/025 (20060101); E04F 11/09 (20060101);