Stair tread protection system
A protector device for protecting a stair tread has a base portion adapted to cover at least a portion of a stair tread and upon which a user can step. The base portion has a forward edge adapted to be generally aligned with a forward edge of the stair tread. The device further includes a clip portion extending from the forward edge of the base portion and adapted to secure the protector device to the stair tread.
This application claims the benefit under 35 USC 119(e) of U.S. Provisional Application No. 60/598,125, which was filed on Aug. 3, 2004, and the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTIONThis invention relates to a device for protecting stair treads and a stair system using a tread protector device.
BACKGROUND OF THE INVENTIONStairs such as those installed in residential homes can be made of costly but decorative materials. For example, stairs can be made of hardwood such as oak or cherry. A finished staircase is typically built in a location remote from the site of final installation. Once built, the staircase is shipped to the installation location and then installed as required. The staircase is generally installed prior to completion of construction of the home or other building, and is used during construction of the building to gain access to upper floors.
A staircase is susceptible to damage during shipping, installation, and use prior to completion of construction of the building in which the stairs are installed. The stair treads (the upper surfaces of the horizontal step portions of the staircase) are particularly susceptible to damage. Workers using the stairs can damage the treads with work boots or by embedding nails or other objects in the treads.
To help protect the stairs, it is known to cover the stairs with a loose fitting plastic wrap. Such a wrap can help keep paint and other debris off the stairs, but does not generally offer significant protection against damage such as that which may be caused by impact to the stairs, or by imbedding objects into the stairs. Securing a sheet of wood onto the upper surface of the treads can improve protection, but this can be time-consuming, costly, and, upon removal, can leave nail or staple marks in the finished staircase.
SUMMARY OF THE INVENTIONIt is an object of this invention to provide a method and apparatus suitable for protecting stairs from certain types of damage. In particular, this invention provides a protector device for stair treads that can be installed in a press-fit or snap-fit arrangement on the stairs, without need for using any nails, staples, or the like to secure the protector device to the stair treads. Moreover, the present invention provides a system for protecting stairs including providing stairs with a first retaining element along the underside of the tread nose, and a stair protector with a second retaining element for engaging the first retaining element in snap-fit when the protector is installed on the stair.
According to a first aspect of the invention, a protector device for protecting a stair tread has a base portion adapted to cover at least a portion of a stair tread and upon which a user can step. The base portion has a forward edge adapted to be generally aligned with a forward edge of the stair tread. The protector is further provided with a clip portion extending from the forward edge of the base portion and adapted to secure the protector device to the stair tread.
The clip portion can have an offset arm extending from the forward edge of the base portion, and a retaining member extending from the offset arm, opposite the base portion. The retaining member can be movable between open and closed positions, wherein in the closed position, the retaining member is adapted to bear against the underside surface of the tread and the clip portion exerts a clamping force across the thickness of the tread. The retaining member can be biased toward the closed position. The clip portion can have a generally C-shaped configuration.
According to a second aspect of the present invention, a system for protecting stairs includes a stair tread in combination with a tread protector device. The protector device can have a tread connection element that can be in the form of a tooth or barb for engaging the underside surface of a tread. The tread can have a protector device connection element for interengaging with the tread connector element to enhance the attachment between the protector device and the tread. The protector device connection element of the tread can be in the form of a groove provided in the underside surface of the tread and adapted to receive the tread connection element of the protector device.
According to a third aspect of the present invention, a protector device for protecting stair treads is provided with a template portion. The template portion can facilitate the installation of staircase accessories, such as balusters for a handrail, to the treads. The template portion can include template features such as holes, cut-outs, or a visible design punched or pressed into the protector device.
BRIEF DESCRIPTION OF THE INVENTIONFor a better understanding of the present invention and to show more clearly how it would be carried into effect, reference will now be made by way of example, to the accompanying drawings that show a preferred embodiment of the present invention, and in which:
A stair tread protector device 10 according to the present invention is shown in
As best seen in
For the embodiment of the staircase 14 illustrated in
Referring to
The distance between the side edges 36 and 38 defines a width that is generally transverse to the depth and that can be about the same size as the width of the tread 12. Alternatively, the width of the base portion 30 can be less than the width of the tread 12, and the base portion 30 can be adapted to cover only a portion of the upper surface 22 of the tread 12. The width and depth of the base portion 30 are preferably sufficient to provide a base portion 30 that is large enough to present a surface upon which a user can step when using the staircase 14. Preferably the base portion 30 is adapted to cover at least a portion of the upper surface 22 of the tread 12 where a user is most likely to step, such as, for example, a central portion of the upper surface 22.
Referring now to
The clip portion 40 can be adapted to exert a clamping force across the thickness of the nose 28 of the tread 12. For example, the retaining member 44 can be movable between open and closed positions. In the closed position, and prior to assembly of the device 10 on tread 12 (
For the embodiment illustrated, the clip portion 40 extends generally continuously along the forward end of the base portion 30. The offset leg 42 of the clip portion 40 extends from the front boundary 32 of the base portion 30 to a lower edge 46. The lower edge 46 is generally parallel to and spaced apart from the front boundary 32. The spacing between the front boundary 32 and lower edge 46 is sized to span the thickness of the tread 12 at the front face 18.
The retaining member 44 has a generally planar extension portion 50 that is positioned generally opposite a forward portion of the base portion 30. The mutually interior facing surfaces of the forward portion of the base portion 30, the offset leg 42, and the extension portion 50 of the retaining member 44 form a recess or cavity 51 at the forward end of the protector device 10. In the relaxed, closed position, the extension portion 50 of the retaining member 44 is inclined to converge towards the base portion 30 rearwardly from the offset panel 42. The converging retaining member 44 provides the cavity 51 with an opening width 53 at its rearward end that is narrower than the thickness of the tread 12, and narrower than the width of the cavity 51 adjacent its front end, near the offset leg 42 (
The protector device 10 can be constructed of a plastic material that is durable, tough, and resistant to impact. The material of the device 10 can also be selected to provide resilient flexibility for the clip portion 40 of the device 10. In the embodiment illustrated, the material of the device 10 is of recycled PVC. The device 10 is manufactured with the clip portion 40 in the closed position, and the clip portion can be urged towards the open position against the force of the resiliently flexible material in the clip portion 40.
The device 10 can be adapted to facilitate manufacture of the device 10 by an extrusion process. For example, the profile of the device 10 in cross-section can extend continuously and uniformly in a direction generally parallel to the front boundary 32. The device 10 can be extruded through one or more dies producing the desired profile. The extrusion can be cut to length, the cuts corresponding to the left and right side edges 36 and 38, respectively, of the base portion 30. A punch or cutting process can be used to produce non-continuous features, such as, for example, but not limited to, a shortened or segmented clip portion 40. For the embodiment illustrated, the device 10 is of one-piece, contiguous extruded plastic construction. Other methods and materials for constructing the protector device 10 can also be used.
In use, as seen in
The clip portion 40 of the device 10 can be pressed over the tread nose 28, urging the clip portion from the closed position towards the open position and forcing a forward portion of the tread nose 28 through the narrowed opening 53 of the cavity 51. The biasing force of the clip portion 40 can exert a clamping force across the thickness of the tread nose 28 to facilitate securing the protector device 10 to the tread 12.
As best seen in
For the embodiment illustrated, the protrusion 58 is adapted to be formed during the extrusion of the device 10, so that the device 10 is of one-piece, unitary construction. The protrusion 58 extends generally across the width of the retaining member 44 of the clip portion 40 of the protector device 10, adjacent the rearward edge of the extension portion 50. Furthermore, for the embodiment illustrated, the protrusion 58 is saw-tooth shaped in cross-section, and has a pointed upper edge 59 that can bite into the underside surface 24 of the tread nose 28. Other configurations of the protrusion 58 can also be provided, such as, for example, but not limited to, one or more discrete (non-continuous) protrusions provided intermittently along the width of the retaining member 44 of the clip portion 40.
Furthermore, and with reference again to
The protrusion 58 and groove 61 can be shaped to inhibit any inadvertent forwardly directed shifting of the protector device 10 off of the tread nose 28. For example, in the embodiment illustrated, the ridge 58 and groove 60 have generally perpendicular forward abutment surfaces 62 and 64, respectively. The generally perpendicular configuration can resist a much greater laterally (horizontally) directed separating force than if the abutting surfaces were inclined at an angle substantially less than 90° to the horizontal.
Referring to
The protector device 10 can be removed from the tread 12 when, for example, other construction work around the staircase 14 has been completed. To remove the protector device 10, the retaining member 44 can be pulled downward to disengage the underside of the tread 12, and the protector device 10 can then be pulled forward so that the tread nose 28 is no longer within the cavity 51 of the device 10. The protector device 10 can then be saved for re-use later. Alternatively, where the device 10 is constructed of plastic, the device 10 can be returned to a plastics recycling operation.
As best seen in
Referring to
Referring now to
The template portion 80 of the device 10 can be provided integrally within the base portion 30 of the device 10. The template portion 80 can include template features (also referred to as target elements) 84, such as, for example, but not limited to, holes, cut-outs, or a visible design provided in pre-determined locations in the material of the device 10. The target elements 84 of the template portion 80 can be punched, pressed, or embossed in the material of the device 10.
For the embodiment illustrated, the template portion 80 of the device 10 includes features 84 in the form of a pair of cut-outs 85 along a marginal portion (the right side) 38 of the base portion 30. An example of how the cut-outs 85 can facilitate the installation of the balusters 82 is explained as follows, with reference also to
In a typical mounting system, the balusters 82 each have a lower end or foot 86 that is typically provided with a dowel pin 88 extending axially downward therefrom. Corresponding holes 90 are drilled in the treads 12 to allow insertion of the dowel pins 88 for mounting the balusters 82. Accordingly, a person installing the balusters 82 drills the holes 90 in the treads 12 of the staircase 14 before installing the balusters 82. In a known method for installing balusters 82, short strips of wood (or other material) are nailed or stapled to the upper surface of each tread 12 to mark the locations where the balusters 82 are to be mounted, and hence, where the holes 90 are to be drilled. The strips essentially serve as a guide or jig, so that a handrail installer can quickly move from tread to tread, accurately positioning and drilling the required holes 90 in each tread. The strips are typically provided to abut an outer edge of the foot 86 of a baluster 82, so that the strips themselves need not be removed until the balusters 82 have been installed. Installing the strips to mark the location for the balusters can be time consuming, and can leave additional nail or staple marks in the treads 12, resulting in additional damage to the treads 12.
Providing the cut-outs 85 of the template portion 80 of the protector devices 10 can conveniently eliminate the need for constructing separate jig elements on each tread 12 for installation of the balusters 82. The cut-outs 85 can provide an accurate guide on each tread 12 for installing the balusters 82. The staircase manufacturer can ensure that the protector devices 10 are accurately positioned on each tread 12 by, for example, aligning either the right or left edge of device 10 with the corresponding edge of the tread 12. Each cut-out 85 can have a shape to generally accommodate the foot 86 of each baluster 82. The protector devices 10 can remain in place after the balusters 82 have been installed (
The template portion 80 can be modified within the scope of the invention. For example, in alternate embodiments of the template portion 80 of the device 10, the template features 84 can comprise perforated or scored lines of weakness to define a break-away panel that can easily be removed to reveal a cut-out 85. Providing lines of weakness instead of an open cut-out can simplify manufacture of the device 10. Furthermore, a visual cue, such as a hole or pattern, can be provided in the break-away panel to specifically mark where holes 90 are to be drilled for the pins 88 of the balusters 82. An installer can first drill holes 90, using the visual cues, and then subsequently remove the break-away panel, prior to installing the baluster 82. This embodiment can further enhance alignment of the balusters 82, and improve accuracy of the location of the holes 90.
Referring now to
Referring now to
Referring to
It is to be understood that what has been described are preferred embodiments of the invention. The invention nonetheless is susceptible to certain changes and alternative embodiments without departing from the subject invention, the scope of which is defined in the following claims.
Claims
1. A protector device for protecting a stair tread, comprising:
- a) a base portion adapted to cover at least a portion of a stair tread and upon which a user can step, the base portion having a forward protector edge adapted to be generally aligned with a forward tread edge of the stair tread; and
- b) a clip portion extending from the forward protector edge of the base portion and adapted to releasably secure the protector device to a stair tread.
2. The device of claim 1 wherein the clip portion comprises an offset arm extending from the forward protector edge of the base portion, and a retaining member extending from the offset arm, opposite the base portion.
3. The device of claim 2 wherein the retaining member is movable between open and closed positions, wherein in the closed position, the retaining member is adapted to bear against the underside surface of the tread such that the clip portion exerts a clamping force across the thickness of the tread.
4. The device of claim 3 wherein the retaining member is biased toward the closed position.
5. The device of claim 4 wherein the clip portion is made of a flexibly resilient material, the retaining member being urged apart from the base portion to move the retaining member to the open position.
6. The device of claim 2 wherein the clip portion comprises a tread connection element for providing releasable locking engagement with a stair tread.
7. The device of claim 6 wherein the tread connection element comprises a barb protruding from the retaining member towards the base portion.
8. The device of claim 1 wherein the clip portion has a generally C-shaped configuration.
9. The device of claim 1 wherein the clip portion extends generally continuously along the forward protector edge of the base portion.
10. The device of claim 1, wherein the device is of one-piece, contiguous extruded plastic construction.
11. In combination, a stair tread and a tread protector device for protecting the stair tread, the stair tread having a forward tread edge, and the tread protector device including a base portion adapted to cover at least a portion of the stair tread and upon which a user can step, the base portion having a forward protector edge adapted to be generally aligned with the forward tread edge of the stair tread, and the protector device having a clip portion extending from the forward protector edge of the base portion and adapted to releasably secure the protector device to the stair tread.
12. The combination of claim 11 wherein the clip portion comprises an offset arm extending from the forward protector edge of the base portion, and a retaining member extending from the offset arm, opposite the base portion.
13. The combination of claim 12 wherein the protector device comprises a tread connection element for providing releasable locking engagement with the stair tread.
14. The combination of claim 13 wherein the stair tread comprises a protector device connection element for inter-engaging with the tread connection element of the protector device.
15. The combination of claim 14 wherein the stair tread has an upper surface covered by the base portion of the protector device, and an underside surface opposite the upper surface, and wherein the protector device connection element comprises a groove provided in the underside surface of the stair tread and the tread connection element comprises a barb for engaging the groove.
16. A protector device for protecting a stair tread, comprising:
- a) a base portion adapted to cover at least a portion of a stair tread and upon which a user can step, the base portion having a forward protector edge adapted to be generally aligned with a forward tread edge of the stair tread; and
- b) a template portion extending marginally of the base portion for facilitating installation of balusters to a stair tread.
17. The protector device of claim 16 wherein the template portion comprises at least one target element to visibly identify a mounting location for a baluster on a stair tread.
18. The protector device of claim 17 further comprising a clip portion extending from the forward protector edge of the base portion and adapted to secure the protector device to a stair tread.
19. The device of claim 18 wherein the clip portion comprises an offset arm extending from the forward protector edge of the base portion, and a retaining member extending from the offset arm, opposite the base portion.
Type: Application
Filed: Aug 3, 2005
Publication Date: Oct 19, 2006
Inventor: Francesco Giordano (Woodbridge)
Application Number: 11/195,617
International Classification: E04F 11/00 (20060101); E04F 19/10 (20060101);