MODULAR STAIRCASE SYSTEMS
Modular staircases and staircase assemblies comprising components with notches that fit into and interweave with each other. Certain embodiments of modular staircases have at least two webs, wherein the perimeter of each web resembles a staircase with steps. The webs may be coupled together by a plurality of cross-beams. Each of the webs and the cross-beams may have notches that fit into and interweave with each other to form the basic structure of a staircase. The staircase may also be provided with cover pieces to cover the exposed webs and cross beams, and thus, to provide a surface for a user to sit or step on. Embodiments described herein are modular, in that they may be coupled together in various configurations and thus coupled to straight walls, curved walls, or any combination thereof. Additionally, embodiments described herein may be installed in either vinyl liner-type pools or concrete pools.
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This application is a non-provisional application of U.S. Application Ser. No. 61/429,299, filed on Jan. 3, 2011 and entitled “Modular Staircase Systems,” the entire contents of which is incorporated by reference.
FIELD OF THE INVENTIONEmbodiments of the invention relate to a staircase to be installed in the interior of a swimming pool, and in particular, to a modular staircase constructed from sheets of material having notches that interweave with each other.
BACKGROUND OF THE INVENTIONPresently, it is known to use various types of steps or staircases in the interior of a swimming pool to allow swimmers to gain access to and exit the swimming pool. One design characteristic of such staircases is the ability to withstand the forces caused by both water pressure within the pool and by the weight of people using the staircase. Another design characteristic is the ability of the staircase to look aesthetically pleasing in the pools. For example, one type of swimming pool may include a “vinyl liner-type” swimming pool. A vinyl liner-type swimming pool is often lined in a sheet of blue-colored vinyl to make the pool appear blue. Thus, if a staircase is to be used in a vinyl liner-type pool, it may be desirable to line the staircase in vinyl such that the staircase blends into the pool walls and looks aesthetically pleasing. And finally, another design characteristic is the ability of the staircase to be used in swimming pools having different shapes or sizes. There may be small pools and large pools, or pools having curved or straight walls (or a combination of the two). Each shape of pool may require a different shaped staircase. It may be desirable to provide a staircase that can be constructed or modified to fit pools having various shapes.
One style of staircase that is often used in swimming pools constructed of concrete (or gunnite) is a concrete-filled staircase. The concrete-filled staircase is built on-site using a step form. The step form is filled with concrete, and when the concrete has set and dried, the step form is removed. Manufacturing concrete steps is expensive and labor intensive, and requires highly skilled workers for construction. Additionally, when concrete-filled steps are used in vinyl liner-type swimming pools, variations in the shape of the steps may make it difficult to cover the steps in vinyl. The uncovered concrete steps may not be aesthetically pleasing.
Another style of staircase is a one-piece molded plastic staircase. Such one-piece staircases have minimal structure to support the weight of swimmers and water pressure forces, and as a result, one-piece staircases have size limitations. Specifically, as the size increases, one-piece staircases lose stability. It is also expensive to manufacture such one-piece staircases, because a separate mold is required for each style and shape of staircase. Simple variations between staircases (for example, the addition or subtraction of a step or the curve of a pool wall) would require a completely new (and expensive) mold. One-piece staircases may be large and irregularly shaped, which may make them difficult to transport and handle. Finally, one-piece staircases may have face plate systems that are not typically covered with a vinyl sheet, which may not be aesthetically pleasing.
Other known staircases are constructed of steel or other metals. Such staircases are often assembled using mechanical fasteners such as screws and bolts. The use of such mechanical fasteners increases assembly time, and thus, increases the overall cost of the staircase. Additionally, the mechanical fasteners are easy to lose and may require the use of special tools to assemble. Finally, the use of steel or other metals is not preferred because metals corrode and rust when used in a pool.
There is a need for a staircase that is adaptable to vinyl liner-type swimming pools.
There is a need for a staircase for use in a pool that is structurally sound and resistant to forces caused by either water weight or users on the staircase, regardless of the size and shape of the staircase.
There is a need for a staircase for use in a pool that is easy to assemble.
There is a need for a staircase made from a non-corrosive material, such as polymer.
There is a need for a staircase that is modular, and thus provides parts that interchange with one another to fit pools having different shapes and sizes.
There is a need to reduce costs associated with special tooling and/or molds used to make the staircase.
SUMMARY OF THE INVENTIONEmbodiments described herein provide a staircase assembled from components that have notches to fit into and interweave with each other. Specifically, one embodiment of a staircase described herein has a plurality of webs, and the perimeter of each web resembles a staircase with steps. The webs may be coupled together by sets of cross-beams. Each of the webs and the cross-beams may have notches that fit into and interweave with each other to form the basic structure of a staircase. The staircase may also be provided with cover pieces to cover the exposed webs and cross beams. The cover pieces provide a smooth and complete surface for a user to sit or step on, and for the vinyl liner to cover. Embodiments of staircases described herein are modular, in that they may be coupled together in various configurations and thus installed in a pool having straight walls, curved walls, or a combination of the two. Additionally, embodiments of staircases described herein may be installed in either vinyl liner-type pools or concrete pools.
A full and enabling disclosure directed to one of ordinary skill in the art is set forth more particularly in the remainder of the specification. The specification makes reference to the following appended figures, in which use of like reference numerals in different features is intended to illustrate like or analogous components.
Embodiments described herein relate to a staircase that can be installed in a swimming pool. For example, the staircase 10 in
The web 12 shown in
Additionally, in certain embodiments the web 12 is provided with cut-outs 30 that include notches 32. The notches 32 may receive cross-beams 50 to provide additional structural support proximate to the bottom edge 22 of the staircase 10. It may be desired to provide a larger shape for cut-out 30 in order to provide room to insert and manipulate the cross beams 50 that are received in the notches 32. Finally, in certain embodiments the web 12 is provided with pre-drilled apertures 28 to receive fasteners to couple a spacing piece 80 to the web 12. The spacing piece 80 is shown in
The specific placement of the first and second cross-beams 50, 60 within the webs 12 is not critical. In certain embodiments, however, it may be desirable to assemble the first cross-beams 50 proximate to the upper steps 14C of the staircase 10, and the second cross-beams 60 proximate to the lower steps 14A. Such an assembly may be desirable in order to provide more structural stability against forces caused by water weight and users on the staircase 10. Specifically, the second cross-beam 60, which may be taller than the first cross-beam 50, may be assembled proximate to the lower steps 14A where the pressure caused by water weight is the greatest. Thus, as shown in
Other embodiments of staircases (not shown) may not include cover pieces 70. Instead, there may be provided cross-beams that are “L” or “T” shaped, having at least one vertical face and at least one horizontal face. The vertical face of the cross-beam may have notches to interweave with the notches of the web, and the horizontal face of the cross-beam may contact the top edges of the web to thus provide a smooth and continuous surface over the web. In this way, “L” or “T” shaped cross-beams may provide an alternate embodiment for a separate cover piece 70.
In another embodiment (such as in
Additionally, first cross-beams 50 may be received within the cut-outs 30 such that the notches 52 on cross beams 50 fit into and interweave with notches 32 of cut-outs 30. Moreover, cross beams 40, 50 may be assembled along the back edges 20 of the webs 12. In the embodiment shown in
In certain embodiments, it may be desirable to couple two staircases together. Different types of staircases (for example, staircase 10, 110, 150) may be coupled together in any order or combination.
The webs 12 may be provided with apertures to receive a bolt or other fastener to couple the two staircases 10 together. When two staircases 10 are coupled together, there may be a gap between the webs 12 of adjoining staircases 10 caused by overhangs 53, 63. To conceal the gap, the cover pieces 70 may be longer than the overall length of the assembled webs 12 such that the cover pieces extend beyond the overhangs 53, 63. In this way, the longer cover pieces 70 conceal the gap between adjoining staircases 10. The gap may also create instability when two staircases 10 are coupled together. Thus, embodiments may be provided with a plurality of spacing pieces 80 coupled to the two outermost webs 12 of each staircase 10. An aperture may be provided in the center of each spacing piece 80 to receive a bolt or other fastener to couple the two staircases 10 together. The spacing piece 80 has a thickness that fills the gap created proximate to each coupling bolt, and thus, improves stability when two staircases 10 are coupled together. While the position of the spacing pieces 80 on the web 12 is not critical, in certain embodiments it may be desirable to position the spacing pieces 80 proximate to edges of the web (for example, at the apex of each step 14A-C, along bottom edge 22 or back edge 20) such that the spacing pieces 80 are easy to access when assembling the staircase 10. The spacing pieces 80 may be coupled to the web 12 with fasteners, adhesive, welding, or any other means known to one of skill in the art. Additionally, the spacing pieces 80 may be coupled to the web 12 either before or after the cross-beams are assembled.
Any of the components of the staircases 10, 110, 150 described herein (for example, webs, cross-beams, reinforcement squares, cover pieces, and back-piece) may be made from sheets of non-corrosive plastic, such as a polymer. For ease of reference, this disclosure references staircase 10, although it should be understood that the disclosure may apply equally to staircase 110, 150. In one specific non-limiting embodiment, the components are made from sheets of acrylonitrile butadiene styrene (ABS) plastic that is 0.4 inch thick, but other thicknesses and types of plastics may be used. In other embodiments, the components are made from other materials, such as wood or metal. The shapes of the various components may be cut out using any type of cutting instrument, such as scissors, a knife or saw, or lasers.
The staircases 10 may be fastened to the walls 100, 112 of the pool with fasteners, adhesive, or other means known to one of skill in the art. If the staircase 10 is installed in a vinyl liner-type pool, then if desired, the staircase 10 may be covered with a vinyl sheet to match the rest of the vinyl liner-type pool. Non-corrosive mechanical fasteners and/or a liner retention strip 38 may be used to couple the vinyl sheet to the staircase 10. But it is not necessary to cover the staircase 10 with a vinyl sheet (for example, if the staircase is installed in a concrete or gunite pool). Embodiments of staircases 10 described herein may support and withstand forces applied by both the water contained within the pool and from users sitting or standing on the staircase 10. Specifically, as shown in
The foregoing is provided for purposes of illustration and disclosure of embodiments of the invention. It will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, it should be understood that the present disclosure has been presented for purposes of example rather than limitation, and does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
Claims
1. A modular system comprising:
- at least two webs, each web comprising a body defined by at least a first step and a second step, and further comprising a first notch defined by the first step and a second notch defined by the second step; and
- at least two cross-beams, each cross-beam comprising a body and at least two notches defined by the body,
- wherein the at least two notches of one cross-beam are dimensioned to fit into and interweave with the first notches on the first steps of the two webs, and wherein the at least two notches of the other cross-beam are dimensioned to fit into and interweave with the second notches on the second steps of the two webs such that the cross-beams couple the webs together and the bodies of the cross-beams are substantially received within the bodies of the webs.
2. A modular system as in claim 1, further comprising: at least two cover pieces, wherein one cover piece is dimensioned to couple to and extend between the first steps of the two webs, and the other cover piece is dimensioned to couple to and extend between the second steps of the two webs.
3. A modular system as in claim 1, wherein the body of each web is further defined by a bottom edge and a side edge perpendicular to the bottom edge, and wherein the first step and the second step are each defined by a rising edge and a running edge.
4. A modular system as in claim 3, wherein the bottom edge is tangent to the first step, the first step is tangent to the second step, and the second step is tangent to the side edge.
5. A modular system as in claim 1, wherein the body of each web defines at least one cut-out, and the cut-out defines a third notch, and wherein the at least two notches of one cross-beam are dimensioned to fit into and interweave with the third notches on the cut-outs of the two webs.
6. A modular system as in claim 3, further comprising a third notch on the side edge of each web, and wherein the at least two notches of one cross-beam are dimensioned to fit into and interweave with the third notches on the side edges of the two webs.
7. A modular system as in claim 3, further comprising a third notch on the side edge of each web, and wherein the modular system further comprises a mounting cross-beam dimensioned to fit into the third notches on the side edges of the two webs.
8. A modular system as in claim 1, wherein at least one of the webs further comprises a cut-out dimensioned to provide a gripping surface for a user's hand.
9. A modular system as in claim 1, wherein the webs and cross-beams are made of a polymer.
10. A modular staircase assembly for installation into a pool having walls, the modular staircase assembly comprising:
- at least a first modular staircase, the first modular staircase comprising:
- at least two webs, each web comprising a body defined by at least two steps and a plurality of notches defined by the steps; and
- at least one cross-beam comprising a body and at least two notches defined in the body,
- wherein one notch of the cross-beam is dimensioned to fit into and interweave with a notch on a step of one web, and the other notch of the cross-beam is dimensioned to fit into and interweave with a notch on a step of the other web such that the cross-beam couples the webs together; and
- at least a second modular staircase coupled to a web of the first modular staircase.
11. A modular staircase assembly as in claim 10, the second modular staircase comprising:
- at least two webs, each web comprising a body defined by at least two steps and a plurality of notches defined by the steps; and
- at least one cross-beam comprising a body and at least two notches defined in the body,
- wherein one notch of the cross-beam is dimensioned to fit into and interweave with a notch on a step of one web, and the other notch of the cross-beam is dimensioned to fit into and interweave with a notch on a step of the other web such that the cross-beam couples the webs together,
- and wherein a web of the second modular staircase is coupled to a web of the first modular staircase.
12. A modular assembly as in claim 11, further comprising at least one spacing piece coupled to a web of the first modular staircase or the second modular staircase, wherein the spacing piece defines an aperture to receive a mechanical fastener to thereby couple the first modular staircase to the second modular staircase.
13. A modular assembly as in claim 11, further comprising a first plurality of cover pieces that are dimensioned to couple to and extend between the steps of the webs of the first modular staircase, and a second plurality of cover pieces that are dimensioned to couple to and extend between the steps of the webs of the second modular staircase.
14. A modular assembly as in claim 13, wherein each cover piece has a length that is dimensioned to cover a gap formed between the first modular staircase and the second modular staircase.
15. A modular staircase assembly as in claim 10, wherein the first modular staircase is dimensioned to couple to a straight portion of a pool wall, and the second modular staircase is dimensioned to couple to a curved portion of a pool wall.
16. A modular staircase assembly as in claim 15, wherein the second modular staircase further comprises at least two cover pieces that are dimensioned to couple to and extend between the steps of the webs of the second modular staircase, and wherein at least one cover piece is defined by at least one curved edge.
17. A modular staircase assembly as in claim 10, further comprising a liner covering the modular staircase assembly and at least a portion of a wall of the pool.
18. A modular system comprising:
- at least two webs, each web comprising a body defined by a bottom edge, a first step proximate to the bottom edge and defining at least one notch, and a second step proximate the first step and defining at least one notch;
- a first cross-beam comprising a body and at least two notches defined in the body; and
- a second cross-beam comprising a body and at least two notches defined in the body,
- wherein the body of the first cross-beam has a height that is greater than a height of the body of the second cross-beam,
- and wherein the at least two notches of the first cross-beam are dimensioned to fit into and interweave with the notches on the first steps of the two webs,
- and wherein the at least two notches of the second cross-beam are dimensioned to fit into and interweave with the notches on the second steps of the two webs such that the cross-beams couple the webs together.
19. A modular system as in claim 18, wherein each of the first step and the second step of each web is defined by a running edge substantially parallel to the bottom edge, and a rising edge perpendicular to the running edge.
20. A modular system as in claim 19, wherein the rising edge and the running edge of the first step and the second step of each web defines a notch.
21. A modular system as in claim 20, further comprising a third cross-beam comprising a body and at least two notches defined in the body; and
- a fourth cross-beam comprising a body and at least two notches defined in the body,
- wherein the third cross-beam has a height substantially equal to the height of the first cross-beam, and the fourth cross-beam has a height equal to the height of the second cross-beam.
22. A modular system as in claim 21,
- wherein the at least two notches of the first cross-beam are dimensioned to fit into and interweave with the notches on the rising edges of the first steps of each web, and
- wherein the at least two notches of the third cross-beam are dimensioned to fit into and interweave with the notches on the running edges of the first steps of each web, and
- wherein the at least two notches of the second cross-beam are dimensioned to fit into and interweave with the notches on the rising edges of the second steps of each web, and
- wherein the at least two notches of the fourth cross-beam are dimensioned to fit into and interweave with the notches on the running edges of the second steps of each web.
23. A modular system as in claim 18, wherein the modular system is enabled to be installed in a pool such that the bottom edges of each web contact a floor of the pool.
24. A modular system as in claim 23, further comprising a liner covering the modular system and at least a portion of the floor of the pool.
25. A modular system as in claim 18, wherein the at least two webs, the first cross-beam, and the second-cross beam are made of a polymer.
Type: Application
Filed: Dec 1, 2011
Publication Date: Jul 5, 2012
Applicant: Latham Pool Products, Inc. (Latham, NY)
Inventors: Harold Albert Brooks (Clifton Park, NY), Matthew Thomas Geyman (Fort Wayne, IN), Shawn Michael Olmsted (Ballston Spa, NY), Gabriel Adam Rice (Huntington, IN)
Application Number: 13/309,324
International Classification: E04F 11/035 (20060101);