Stair Nose Assembly and Method of Installation

Abstract

A two-piece stair nosing assembly is used in new construction and the reconstruction and repair of stairs, primarily for industrial and commercial applications. The stair nosing assembly comprises a metal base member and a metal upper member. The base member includes one or more anchors embedded in uncured concrete which, when cured, secures the base member to the stair pan. The upper member is detachably attached to the base member and can serve as both a protective cover during the cast-in-place process and as a tread surface after the cast-in-place process is completed and the stairs are ready for use.

Description

This application is based on the priority of U.S. provisional application 63/388,081, filed Jul. 11, 2022, and entitled Two-Piece Stair Nosing, which application is hereby incorporated by reference in its entirety and made a part of this Application.

FIELD OF THE INVENTION

The invention relates to a two-piece stair nose.

BACKGROUND OF THE INVENTION

A staircase is typically one of the first parts of a building to be constructed. After the stairs are constructed, they are often used by construction workers while the remainder of the building is constructed and finished. For stairs that have stair nosing, or a stair nose, such nosings or noses are typically installed using cast-in-place processes that require the stair nosing or stair nose to be embedded in the stair pan at the time the concrete is poured into the stair pan. The period of time after the stairs are constructed and before the building is finished can expose the stairs, and particularly the front nose of the stairs, to significant damage and debris. For example, the exposed features of the stair nosings can be scratched, dented or splashed with paint or other materials after the concrete pour but before the building construction has been finished.

To protect the stair nosings during this interim period, stair nosing manufacturers and building contractors use various products and strategies. For example, contractors sometimes place a layer of tape over the upper surfaces of the nosings and then remove the tape after construction of the building is complete. This is an additional step for the contractor and adds labor costs, complexity and the possibility of human error in the placement of the tape. In addition, the tape may not be thick enough or robust enough to protect the stair nosing from impacts.

Accordingly, some stair nosing manufacturers have shipped the stair nosing with a thicker disposable layer (e.g., an elongated wood strip) that stays on the base layer until construction is complete. It is then removed, thrown away and the upper thread member is attached to the base member. An example of such a product is the Cast in/Blockout Stair Nosings models DXH-330-PL-100 and FPH-300-PL-100—available from Balco, Inc of Wichita, KS. However, it is preferable not to have the additional cost of the throw-away layer or the environmental issues related to a single use protective layer and the possibility of the unattached tread member being misplaced during the construction process.

It is desirable not to have a stair nosing assembly that requires taping or masking work by the contractor to protect the stair nosing, or a stair nosing that does not require using thick protective layers that are subsequently thrown away with all the attendant disposal issues.

It is also desirable for the stair nosing assembly to be economically manufacture, easy to install, and is attractive and long-lasting structure.

SUMMARY OF THE INVENTION

Described herein is a stair nosing assembly having an elongated base member with an upper surface and an anchor member. The base member is configured to be mounted in a concrete stair step using a cast-in-place process. The assembly also comprises an elongated upper member. The elongated upper member has a tread surface and an opposing protective cover surface. The upper member is configured so that it is usable as both a protective cover for the base member during the cast-in-place process and also as a tread surface after the cast-in-place process. This can be done by simply flipping over the upper member after the cast-in-place process and reattaching the upper member so that the tread surface is facing upward and the protective cover surface is adjacent to and attached to the top surface of the base member.

In at least one embodiment the tread surface of the upper member is detachably attached adjacent to the upper surface of the base member prior to and during the cast-in-place process. This leaves the opposing protective cover surface facing upward so that it is exposed to potential damage during the construction phase.

In yet another embodiment, both the tread surface and the protective cover surface are covered by a thin film.

In at least one embodiment the tread surface comprises a high friction area and a photoluminescent member.

It is an object of the present invention to provide a stair nosing of relatively simple structure as described in one or more of the appended claims.

Another object of the present invention is to provide a stair nosing structure having interlocking members for ease of assembly and disassembly.

Yet another object is to provide a stair nosing structure which is rugged and long wearing but which can be easily disassembled for repair or replacement if damaged.

The method of installing the present invention comprises: pouring concrete into a stair step pan; placing a stair nosing assembly, having a base member, an upper member, and a protective cover surface between the base and upper members, into the uncured concrete with the base member detachably attached to the upper member and with the protective cover surface of the upper member facing upward; allowing the concrete to cure securing the anchor of the base member in the concrete; following curing of the concrete, removing a film on the protective cover; detaching the upper member from the base member; flipping the upper member over and removing another film on the tread surface; and reattaching the upper member to the base member with the protective cover surface adjacent to the top surface of the base member and the tread surface facing upward.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1(a) is an exploded perspective view of the nosing assembly of the present invention while it is in cast-in-place mode.

FIG. 1(b) is an exploded perspective view of the nosing assembly of the present invention after the upper member has been flipped and it is in “In Use” mode.

FIG. 2 is a cross-sectional view of the tread assembled on a concrete stair pan.

FIG. 3 is a perspective view of the nosing assembly of the present invention.

FIGS. 4(a)-(d) reflect the process steps of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Characteristics and advantages of the present disclosure and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of exemplary embodiments of the present disclosure and referring to the accompanying figures. It should be understood that the description herein and appended drawings, being of example embodiments, are not intended to limit the claims of this patent or any patent or patent application claiming priority hereto. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the claims. Changes may be made to the particular embodiments and details disclosed herein without departing from such spirit and scope.

In showing and describing preferred embodiments in the appended figures, common or similar elements are referenced with like or identical reference numerals or are apparent from the figures and/or the description herein. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness. Like numbers refer to like elements throughout.

As used herein and throughout various portions (and headings) of this patent application, the terms “disclosure”, “present disclosure” and variations thereof are not intended to mean every possible embodiment encompassed by this disclosure or any particular claim(s). Thus, the subject matter of each such reference should not be considered as necessary for, or part of, every embodiment hereof or of any particular claim(s) merely because of such reference.

The term “coupled” and the like, and variations thereof, as used herein and in the appended claims are intended to mean either an indirect or direct connection or engagement. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

Certain terms are used herein and in the appended claims to refer to particular components. As one skilled in the art will appreciate, different persons may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function.

Also, the terms “including,” “having,” and “comprising” are used herein and in the appended claims in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Further, reference herein and in the appended claims to components and aspects in a singular tense does not necessarily limit the present disclosure or appended claims to only one such component or aspect, but should be interpreted generally to mean one or more, as may be suitable and desirable in each particular instance.

Preferred embodiments of the present disclosure thus offer advantages over the prior art and are well adapted to carry out one or more of the objects of this disclosure. However, the present disclosure does not require each of the components and acts described above and are in no way limited to the above-described embodiments or methods of operation. Any one or more of the above components, features and processes may be employed in any suitable configuration without inclusion of other such components, features and processes. Moreover, the present disclosure includes additional features, capabilities, functions, methods, uses and applications that have not been specifically addressed herein but are, or will become, apparent from the description herein, the appended drawings and claims.

The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including at least one of that term (e.g., the colorant(s) includes at least one colorants). “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event occurs and instances where it does not. As used herein, “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like.

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

As used herein and throughout various portions (and headings) of this patent application, the terms “disclosure”, “present disclosure” and variations thereof are not intended to mean every possible embodiment encompassed by this disclosure or any particular claim(s). Thus, the subject matter of each such reference should not be considered as necessary for, or part of, every embodiment hereof or of any particular claim(s) merely because of such reference.

The term “coupled” and the like, and variations thereof, as used herein and in the appended claims are intended to mean either an indirect or direct connection or engagement. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections.

Certain terms are used herein and in the appended claims to refer to particular components. As one skilled in the art will appreciate, different persons may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function.

Referring to FIG. 1(a), stair nosing assembly 10 is shown in the cast-in-place configuration. Anchor 16 permanently attaches base member 15 in the cured concrete (see FIG. 2). Anchor 16 can be any of a number of different shapes and sizes. It is intended to simply assure that base member 15 is firmly embedded in the concrete after the concrete is cured. It needs to be long enough and have enough surface area to make pulling base member 15 out of the cured concrete extremely difficult or impossible. In at least one embodiment, anchor 16 is a ¼″×1″ hex head bolt and nut, 3″ (76 mm) from each end of base member 15 and 12″ (305 mm) O.C. available commercially from Fastenal headquartered in Winona, MN.

Anchor 16 is attached to base member 15 using base member anchor holder 15(c) (see FIG. 2). Anchor holder 15(c), in at least some embodiments, is a slot or cavity that holds anchor 16 in place against base member 15. In some embodiments (not expressly shown) the anchor (or anchors) is an integral part of base member 15.

Base member 15 is an elongated metallic member having an upper surface 15(a) with threaded cavity 15(b). Threaded cavity 15(b) is configured so that upper member 12 can be detachably attached to base member 15 using threaded fastener 11. Threaded fastener 11 goes through an orifice (not visible in FIG. 1(a), 1(b) or 2) in upper member 14 and is then screwed into threaded cavity 15(b) of base member 15 (see FIG. 2). In at least one embodiment, threaded fastener 1 is a 10-24 Torx Flat Head Screw, 3″ (76 mm) from each end of the upper member 14 and 12″ (305 mm) O.C. available commercially from Fastenal headquartered in Winona, MN.

Upper surface 15(a) of base member 5 is configured and sized so that either protective cover surface 14(a) or tread surface 14(c) of upper member 14 can be attached adjacent to upper surface 15(a). In some embodiments, upper surface 15(a) of base member 15 is essentially flat with an upwardly and backwardly facing curve or hook 15(d) that helps keep, along with threaded fastener 11, the front area of upper member 14 in place adjacent to upper surface 15(a) of base member 15. In some embodiments base member 15 is an extruded or cast elongated aluminum member.

Upper member 14, in some embodiments, also has photoluminescent strip 12 that is attached to a recessed portion 14(b) of tread surface 14(c) of upper member 14 using double sided foam tape 13 or some other attachment means. In some embodiments upper member 14 is an extruded or cast elongated aluminum member. Photoluminescent strips are well known in the art and can be bought from a number of manufacturers.

Upper member 14, in some embodiments, also has high friction area 14(d) on tread surface 14(c). In at least one embodiment, slip resistant, high friction area 14(d) is an integral part of tread surface 14(c). In some embodiments, the friction in this area is increased by directionally polishing the metallic surface. In some other embodiments (not expressly shown) the high friction area of the tread surface 14(c) is a separate high friction strip that is attached to tread surface 14(c). Examples of friction strips include suitable elastomeric or polymeric tread materials containing aluminum oxide, silicon carbide or other particulate abrasive to provide a slip-resistant surface. The non-slip material may be bonded to tread surface 14(c) of upper member 14 by techniques well known in the art such as vulcanizing and/or adhesively bonding.

During the cast-in-place process, protective cover surface 14(a) and tread surface 14(c) of upper member 14 are both covered by protective films 17(a) and 17(b). In at least one embodiment protective films 17(a) and 17(b) are available commercially from Evan Evco headquartered in Kansas City, MO.

Referring now to FIGS. 1(b) and 2, a portion of stair nosing assembly 10 has been flipped over and is in the “in use” final configuration. In this configuration tread surface 14(c) has been flipped upward and is facing away from base member 15. This means that protective cover surface 14(a) is adjacent to upper surface 15(a) of base member 15.

FIG. 2 is a cross-sectional view of assembly 10 once embedded into cured concrete 55. Anchor 16 holds the base member 15 in place in the cured concrete and fasteners 11 secure upper member 14 to base member 15.

FIG. 3 is a perspective view of a finished stair nose assembly 10 that is not embedded in concrete. Again, this view shows high friction area 14(d), photoluminescent strip 12, base member 15 and upper member 14 facing upwardly and available for use for persons walking on the stairs following construction.

In yet another embodiment of the invention, a method is described for assembling stair nosing assembly 10 onto a concrete stair pan. The method of installing stair nosing assembly 10 during the cast-in-place process comprises, inter alia, the following steps: pouring concrete mix into a step pan; placing stair nosing assembly 10 into the uncured concrete 55 with base member 15 detachably attached to upper member 14 with protective cover surface 14(a) of upper member 14 facing upward; allowing the concrete to cure securing anchor 16 of base member 15 in the concrete; following curing of the concrete, detaching upper member 14 from base member 15 by unscrewing threaded fastener 11 from threaded cavity 15(b); removing film 17(a) on protective cover surface 14(a) of upper member 14; flipping upper member 14 over and removing film 17(b) on tread surface 4(c); reattaching upper member 14 to base member 15 with protective cover surface 14(a) adjacent to upper surface 15(a) of base member 15 and tread surface 14(c) facing up for use by persons walking on the stairs following construction.

That is, referring now to FIGS. 4(a)-(d), the process begins with pouring concrete 40 into a stair pan 50. Stair nose assembly 10 is inserted in the concrete with anchors 16 holding base member 15 in place. During this step upper member 14 is in an inverted position with protective surface 14(a) of the upper member facing upwardly as discussed above. Thus, tread surface 14(c), photoluminescent strip 12, and other final surface features of the top surface of the upper member 14 when in final position after curing will be protected from wet concrete debris and other construction activities during the installation phase. After the concrete is cured, as shown in FIG. 4(b), upper member 14 is detached from base member 15 by unscrewing threaded fasteners 11. Film 17(a) is then peeled off protective cover surface 14(c) and film 17(b) is peeled off thread surface 14(c) as discussed above. Referring now to FIG. 4(c), upper member 14 is then flipped over as reflected by arrow 25 and reattached to base member 15 with fasteners 11 so that tread surface 14(c), high friction area 14(d) and photoluminescent strip 12 face upwardly in the final configuration for use by persons walking on the stairs.

Although the invention has been described with particular reference to specific embodiments, it should be understood that other variations may be used without departing from the basic concept. For example, different materials of construction can be used then those specifically stated herein. Furthermore, various modifications can be made in the design and the inter-engagement of the base member and upper member. A variety of choices can be used for selecting fasteners and anchors. Furthermore, the process or method claims are not limited to the order specified in the claims. The claimed process is intended to cover all processes performed by using steps that may deviate from the order specified if the result from the performance of the process is substantially the same result. Thus, the invention is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.

Claims

1. A stair nose assembly comprising:

An elongated base member having an upper surface and an anchor member, said base member being configured to be mounted in a concrete stair step using a cast-in-place process; and

An elongated upper member having a tread surface and an opposing protective cover surface configured so that the upper member protects the base member during the cast-in-place process and as a tread surface after the cast-in-place process.

2. The stair nose assembly of claim 1 wherein the tread surface of the upper member contacts the upper surface of the base member prior to and during the cast-in-place process.

3. The stair nose assembly of claim 1 further comprising a first film covering the tread surface and a second film covering the opposed protective cover surface.

4. The stair nose assembly of claim 1 wherein the tread surface of the upper member includes a high friction area.

5. The stair nose assembly of claim 1 further comprising a photoluminescent member supported by the tread surface.

6. A stair nose assembly comprising:

An elongated base member having an upper surface and an anchor member, said base member being configured to be mounted in a concrete stair step using a cast-in-place process;

An elongated upper member having a tread surface and an opposing protective cover surface configured so that the upper member protects the base member during the cast-in-place process and as a tread surface after the cast-in-place process;

a first film covering the tread surface; and

a second film covering the opposed protective cover surface,

wherein the tread surface of the upper member contacts the upper surface of the base member prior to and during the cast-in-place process.

7. The stair nose assembly of claim 6 wherein the tread surface of the upper member includes a high friction area.

8. The stair nose assembly of claim 6 further comprising a photoluminescent member supported by the tread surface.

9. A stair nose assembly comprising:

An elongated base member having an upper surface and an anchor member, said base member being configured to be mounted in a concrete stair step using a cast-in-place process;

An elongated upper member having a tread surface and an opposing protective cover surface configured so that the upper member protects the base member during the cast-in-place process and as a tread surface after the cast-in-place process;

a first film covering the tread surface;

a second film covering the opposed protective cover surface;

a photoluminescent member supported by the tread surface,

wherein the tread surface of the upper member contacts the upper surface of the base member prior to and during the cast-in-place process.

10. The stair nose assembly of claim 6 wherein the tread surface of the upper member includes a high friction area.

11. A method of installing the stair nosing assembly comprising the steps of:

providing a stair nose assembly having a base member with an upper surface, an upper member having a tread surface and an opposing protective cover surface, a first film covering the tread surface; and a second film covering the opposed protective cover surface,

pouring concrete mix into a step pan;

placing the stair nosing assembly into the uncured concrete with the base member detachably attached to the upper member and with the protective cover surface of the upper member facing upward;

following curing of the concrete, detaching the upper member from the base member;

flipping the upper member over and removing the first film on the tread surface;

removing the second film from the protective cover surface; and

reattaching the upper member to the base member with the protective cover side adjacent to the upper surface of the base member and the tread surface facing up.