STEP COVER AND STAIR COVER SYSTEM

Abstract

A step cover and a stair cover system. The step cover includes a flat tread, a length of extruded plastic cap, and a spline. The tread having a front, two sides, and a back, a lower surface and an upper surface, at least the upper surface wrapped with a decorative film, the front and the sides each having a groove, the length of plastic cap having a curved cross section with two ends, an outer surface and an inner surface, a curved front, said back having two straight edges between the ends, at least one of the edges having a groove, the outer surface of the plastic cap wrapped with a decorative film, and the spline having a top surface and a bottom surface, the spline configured to fit into grooves in the tread and the plastic cap.

Claims

1. A step cover for covering a step comprising: a flat tread having a front, two sides, and a back, a lower surface and an upper surface, a width from one side to the other side and a depth from front to back, at least said upper surface wrapped with a decorative film, said front having a groove; a length of extruded plastic cap curved in cross section having two ends, said plastic cap having an outer surface and an inner surface, said plastic cap having a width between said two ends, a curved front, said back having two straight edges between said ends along said width, at least one of the edges having a groove between said ends, and said outer surface of said plastic cap wrapped with a decorative film; and a thin spline having a top surface and a bottom surface, said spline configured to fit into said groove in said tread on a first side of said spline and into said groove in said plastic cap on a second side of said spline when said front of said tread and said edge of said plastic cap are adjoined with said spline positioned between them; wherein, said decorative film on said tread is substantially similar in appearance to said decorative film on said plastic cap; wherein said tread can be connected to said plastic cap along said front of said tread and along one of said edges of said plastic cap using said spline with said spline positioned in said grooves.

2. The step cover of claim 1, wherein said spline includes ridges on at least one of said top surface and said bottom surface.

3. The step cover of claim 2, wherein said tread is fixedly attached to said plastic cap using said spline positioned in said grooves and with adhesive on said spline and inside said grooves.

4. The step cover of claim 1, wherein said back of said plastic cap is concave shaped configured to fit over a front full bullnose edge of a step.

5. The step cover of claim 3, further comprising a second plastic cap, said second plastic cap curved in cross section having two ends, said second plastic cap having an outer surface and an inner surface, said second plastic cap having a width between said two ends, a curved front, said back having two straight edges between said ends along said width, at least one of the edges having a groove between said ends, and said outer surface of said second plastic nose wrapped with a decorative film, wherein said tread is fixedly attached to said second plastic cap using a spline positioned in a groove of said second plastic cap and in said groove in one of said sides of said tread.

6. The step cover of claim 5, further comprising a third plastic cap, said third plastic cap curved in cross section having two ends, said second plastic cap having an outer surface and an inner surface, said third plastic cap having a width between said two ends, a curved front, said back having two straight edges between said ends along said width, at least one of the edges having a groove between said ends, and said outer surface of said third plastic cap wrapped with a decorative film, wherein said third plastic nose is fixedly attached to said second plastic cap using a spline positioned in said groove of said second plastic cap and in said groove in said third plastic cap.

7. The step cover of claim 1, further comprising a length of wood stair nosing having a full bullnose front and a flat back configured to attach to a flat front step, wherein said back of said plastic cap is configured to fit over said front full bullnose edge of said length of wood stair nosing.

8. The step cover of claim 1, further comprising a step riser cover having a front and a back, and four sides, with a decorative film or paper or laminate on a front surface and on the four sides.

9. A step cover for covering a step comprising: a flat tread having a front, two sides, and a back, a lower surface and an upper surface, a width from one side to the other side and a depth from front to back, at least said upper surface wrapped with a decorative film, paper or laminate, said front and at least one of said sides having a groove; at least one length of extruded plastic nose curved in cross section having two ends, said at least one length of plastic nose having an outer surface and an inner surface, said at least one length of plastic nose having a width between said two ends, a curved front and a concave back, said back having two straight edges between said ends along said width, at least one of the edges having a groove between said ends, and said outer surface of said at least one plastic nose wrapped with a decorative film, paper or laminate; and at least one thin spline having a top surface and a bottom surface, said at least one spline configured to fit into said groove in said tread on a first side of said at least one spline and into said groove in said plastic nose on a second side of said at least one spline when said front of said tread and said at least one edge of at least one plastic nose are adjoined with said at least one spline positioned between them; wherein said tread can be connected to said at least one plastic nose along said front of said tread and along one of said edges of said at least one plastic nose using said spline with said spline positioned in said grooves.

10. The step cover of claim 9, wherein said at least one spline includes ridges on at least one of said top surface and said bottom surface.

11. The step cover of claim 10, wherein said tread is fixedly attached to said plastic nose using said spline positioned in said grooves and with adhesive on said spline and inside said grooves.

12. The step cover of claim 9, further comprising a length of wood stair nosing having a full bullnose front and a flat back wherein said back of said plastic nose is configured to fit over said front full bullnose edge of said length of wood stair nosing.

13. The step cover of claim 9, wherein said tread is fixedly attached to said plastic nose using said spline positioned in said grooves and with adhesive on said spline and inside said grooves.

14. The step cover of claim 9, further comprising a second extruded plastic nose, wherein said tread can be connected to said second plastic nose along a side of said tread and along one of said edges of said second plastic nose using a second spline with said second spline positioned in said grooves.

15. The step cover of claim 14, further comprising a third length of extruded plastic nose, wherein said tread can be connected to said third plastic nose along a side of said tread and along one of said edges of said third plastic nose using a third spline with said third spline positioned in said grooves.

16. The step cover of claim 9, wherein said decorative film on said tread is substantially similar in appearance to said decorative film on said plastic nose.

17. The step cover of claim 9, further comprising a step riser cover having a front and a back, and four sides, with a decorative film or paper or laminate on a front surface and on the four sides.

18. A process for covering a step on a closed stringer staircase with flooring material having a preselected decorative film finish said flooring material comprising a flat tread, a cap, and a spline, said flat tread comprising a front, two sides, and a back, a lower surface and an upper surface, a width from one side to the other side and a depth from front to back, at least said upper surface wrapped with a decorative film, said front having a groove along the width of said tread; said cap comprising a length of extruded plastic curved in cross section having two ends, said cap having an outer surface and an inner surface, a width between said two ends, a curved front and a concave back, said back having two straight edges between said ends along said width, at least one of said edges having a groove between said ends, said outer surface of said cap wrapped with a decorative film; a length of spline having a top surface and a bottom surface, said spline configured to fit into said groove in said tread on a first side of said spline and into said groove in said cap on a second side of said spline when said front of said tread and a said edge of said cap are adjoined with said spline positioned between them; the process comprising: cutting said tread, said cap, and said spline to a desired width for a step to be covered determined by the width of the step between stringers; cutting said tread to a depth determined by measuring the distance from the riser to the edge of said cap with said cap positioned over the front edge of the step; fixedly connecting said cap to said tread using said spline and adhesive, with said spline positioned inside said groove of said tread and said groove in said edge of said cap; and fixedly attaching said connected cap and tread to said step using adhesive placed on said step.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0015] The foregoing summary, as well as the following detailed description of the exemplary embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings exemplary embodiments. It should be understood, however, that the subject disclosure is not limited to the precise arrangements and instrumentalities shown.

[0016] In the drawings:

[0017] FIGS. 1-7 show a first exemplary embodiment for steps with closed stringers comprising a cap, a tread and a spline;

[0018] FIG. 1 is an exploded view of the cap, tread and spline cut to the desired width for the step;

[0019] FIG. 2 is an enlarged partial exploded view of the cap, tread and spline shown in FIG. 1 showing ridges in the surface of the spline;

[0020] FIG. 3 shows the cap, tread and spline in FIG. 2 assembled together with the cut spline positioned in the grooves in the cap and the tread;

[0021] FIG. 4 shows the tread in FIGS. 1-3 with the corner of the decorative film, paper or laminate lifted showing the substrate beneath;

[0022] FIGS. 5-7 show the cap, tread and spline in FIGS. 1-4 assembled together being installed onto the step showing the depth D of the tread cut for the step;

[0023] FIG. 6 shows the assembled step cover installed on the step.

[0024] FIGS. 8-12 show a second exemplary embodiment for a step with a return on one side (closed stringer on one side even though shown open) comprising three pieces of cap, a tread and three pieces of spline;

[0025] FIG. 8 is an exploded view of the caps, tread and splines cut and mitered for the step;

[0026] FIGS. 9-10 show the tread and first and second splines in FIG. 8 assembled together being installed onto the step showing the depth D of the tread cut for the step;

[0027] FIGS. 11-12 show the assembled step cover installed on the step.

[0028] FIG. 13 shows a cap in accordance with another exemplary embodiment without a spline by forming one of the edges of the cap with a tongue instead of a groove.

DETAILED DESCRIPTION OF THE INVENTION

[0029] Reference will now be made in detail to the various exemplary embodiments of the subject disclosure illustrated in the accompanying drawings. Wherever possible, the same or like reference numbers will be used throughout the drawings to refer to the same or like features. It should be noted that the drawings are in simplified form and are not drawn to precise scale. Certain terminology is used in the following description for convenience only and is not limiting. Directional terms such as top, bottom, left, right, above, below and diagonal, are used with respect to the accompanying drawings. The term “distal” shall mean away from the center of a body. The term “proximal” shall mean closer towards the center of a body and/or away from the “distal” end. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the identified element and designated parts thereof. Such directional terms used in conjunction with the following description of the drawings should not be construed to limit the scope of the subject disclosure in any manner not explicitly set forth. Additionally, the term “a,” as used in the specification, means “at least one.” The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.

[0030] “About” as used herein when referring to a measurable value such as an amount, a temporal duration, and the like, is meant to encompass variations of ±20%, ±10%, ±5%, ±1%, or ±0.1% from the specified value, as such variations are appropriate.

[0031] “Substantially” as used herein shall mean considerable in extent, largely but not wholly that which is specified, or an appropriate variation therefrom as is acceptable within the field of art. “Exemplary” as used herein shall mean serving as an example.

[0032] Throughout this disclosure, various aspects of the subject disclosure can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the subject disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, and 6. This applies regardless of the breadth of the range.

[0033] Furthermore, the described features, advantages and characteristics of the exemplary embodiments of the subject disclosure may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize, in light of the description herein, that the present disclosure can be practiced without one or more of the specific features or advantages of a particular exemplary embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all exemplary embodiments of the subject disclosure.

[0034] Referring now to FIGS. 1-7, there is shown an exemplary step cover 10. As illustrated in FIGS. 1-7, the step cover 10 includes:

[0035] a flat tread 20 having a front 22, two sides 24 and 25, and a back 26, a lower surface 27 and an upper surface 29, a width W from one side 24 to the other side 25 and a depth D from front 22 to back 26, at least said upper surface 29 wrapped with a decorative film, paper or laminate, said front 22 having a groove 21;

[0036] a length of extruded plastic cap 30 curved in cross section having two ends 34 and 35, said plastic cap 30 having an outer surface 39 and an inner surface 37, said plastic cap 30 having a width W between said two ends 34 and 35, a curved front 32 and a curved back 33, said back 33 having two straight edges 38 between said ends along said width W, one on top and one on bottom, at least one of the edges 38 having a groove 31 between said ends 34 and 35, and said outer surface 39 of said plastic cap 30 wrapped with a decorative film, paper or laminate;

[0037] and a thin spline 40 having a top surface 49 and a bottom surface 47, said spline 40 configured to fit into said groove 21 in said tread 20 on a first side of said spline and into said groove 31 in said plastic cap 30 on a second side of said spline when said front 22 of said tread 20 and said edge 38 of said plastic cap 30 are adjoined with said spline 40 positioned between them;

[0038] wherein, said decorative film, paper or laminate on said tread 20 is substantially similar in appearance to said decorative film, paper or laminate on said plastic cap 30;

[0039] wherein said tread 20 can be connected to said plastic cap 30 along said front 22 of said tread 20 and along one of said edges 38 of said plastic cap 30 using said spline 40 with said spline 40 positioned in said grooves 22 and 38.

[0040] The spline 40 for the decorative step cover 10 can be made smooth on top 49 and bottom 47 or, more preferably, it can be made with uneven surfaces such as with indentations and/or ridges along the length of the spline as shown in FIG. 2.

[0041] The back 33 of the plastic cap 30 is concave shaped configured to fit over a front full bullnose edge of a step.

[0042] Once the tread 20, cap 30 and spline 40 are cut to a desired width for covering a step, and the tread 20 is cut to the desired depth, the tread 20 is fixedly connected to the cap 30 using the spline 40. Adhesive (not shown) is applied to the spline 40 which is then placed into the grooves 22 and 38 in the front 22 of the tread 20 and the edge 38 of the cap 30 resulting in contact between the 38 edge of the cap 30 and the front 22 of the tread 20 with the spline 40 concealed inside the grooves 21 and 31. The connected tread and cap (with spline) 10 can then be fixedly installed onto the step using adhesive.

[0043] In accordance with an alternative exemplary embodiment, the tread 20 further includes a groove 21 on at least one of sides 24 and 25 and the step cover 10 also includes a second piece of cap 30 and a second piece of spline 40 for fixedly connecting a return on one side (24 or 25) of the tread 20 as seen in FIGS. 8-12. Preferably, the corner of the step cover 10 where the first and second pieces of cap 30 meet are mitered (e.g., at a 45 degree angle) for an aesthetically pleasing appearance. The second piece of cap 30 can be fixedly attached to the tread 20 using adhesive (not shown) and the second piece of spline 40 concealed inside the grooves 21 and 31. In accordance with an alternative exemplary embodiment, a third piece of cap 30 can be fixedly attached to the step cover 10, preferably with a mitered end as seen in FIGS. 8, 9, 11, and 12, using a third piece of spline 40 concealed inside grooves 21 in the second and third pieces of cap 30.

[0044] The assembly and installation of an exemplary embodiment onto a closed stringer step is as follows. Tread 20, cap 30 and spline 40 are cut to the desired width for covering the front bullnose and the tread on a closed stair tread. Cap 30 is placed over the bullnose of the front of the step and a line is drawn on the step alone the edge 38 of the cap 30. The required depth of the tread 20 is measured on the step from the line drawn to the riser and the tread 20 is cut to the depth on the back end. Tread 20 is fixedly connected to the cap 30 using the spline 40. Adhesive (not shown) is applied to the spline 40 which is then placed into the grooves 22 and 38 in the front 22 of the tread 20 and the edge 38 of the cap 30 resulting in contact between the 38 edge of the cap 30 and the front 22 of the tread 20 with the spline 40 concealed inside the grooves 21 and 31. The connected tread and cap (with spline) 10 can then be fixedly installed onto the step using adhesive.

[0045] The assembly and installation of an exemplary embodiment onto a step with one open end is as follows. Tread 20, cap 30 and spline 40 are cut to the desired width for covering the front bullnose and the tread with the cap 30 and spline 40 having a 45 degree mitered end on the open side of the step (alternatively, as seen in FIG. 8, the front spline can be cut straight and longer than the tread to insert into the groove 31 in the second cap 30). Cap 30 is placed over the bullnose of the front of the step and a line is drawn on the step alone the edge 38 of the cap 30. The required depth of the tread 20 is measured on the step from the line drawn to the riser and the tread 20 is cut to the depth (D) on the back end. Tread 20 is fixedly connected to the cap 30 using the spline 40. Adhesive (not shown) is applied to the spline 40 which is then placed into the grooves 21 and 31 in the front 22 of the tread 20 and the edge 38 of the cap 30 resulting in contact between the 38 edge of the cap 30 and the front 22 of the tread 20 with the spline 40 concealed inside the grooves 21 and 31.

[0046] A second piece of cap 30 and a second piece of spline 40 are cut to length for the side of the step with 45 degree mitered ends on the second piece of cap 30 (alternatively, as seen in FIG. 8, the second spline can be cut shorter than the tread to leave room in the groove 21 for the front spline 40 and third spline 40). The second piece of cap 30 is fixedly attached to the tread 20 using adhesive (not shown) and the second piece of spline 40 concealed inside the grooves 21 and 31. A third piece of cap 30 is cut to length with a 45 degree mitered end on one side and a straight cut on the other. The third piece of cap 30 is attached to the step cover 10 using a third piece of spline 40 positioned in groove 31 in the second piece of cap 30 and the third piece of cap 30 using adhesive (not shown). The assembled step cover 10 can then be fixedly installed onto the step using adhesive as shown in (FIG. 10).

[0047] An alternative exemplary embodiment eliminates the spline by forming one of the edges of the cap with a tongue instead of a groove, the tongue configured to fit into the grooves on the tread. As seen in FIG. 13, there is a length of extruded plastic cap 30 curved in cross section having two ends 34 and 35, said plastic cap 30 having an outer surface 39 and an inner surface 37, said plastic cap 30 having a width W between said two ends 34 and 35, a curved front 32 and a curved back 33, said back 33 having two straight edges 38 between said ends along said width W, one on top and one on bottom, one of the edges 38 having a tongue 36 between said ends 34 and 35, and said outer surface 39 of said plastic cap 30 wrapped with a decorative film, paper or laminate. The tread 20 of the prior exemplary embodiments described above is used with this cap 30 having a tongue 36 to form the step cover 10, cap 30 and tread 20 are cut to the desired width and tread 20 is cut to the desired depth and the two are then fixedly connected together using adhesive with the tongue 36 inserted into groove 21.

[0048] Another exemplary embodiment of the step cover further includes a step riser cover (not shown) having a front and a back, and four sides, with a decorative film or paper or laminate on a front surface and on the four sides. The step riser cover can be used and included as part of the step cover 10 for any of the above described exemplary embodiments. The step riser cover is cut to the width W of the tread 20 and the step riser cover is cut to the desired height H measured by placing the tread 20 on top of the step and measuring the distance from the upper surface 29 of the tread to the underside of the next highest step. The step riser cover is fixedly connected to the riser using adhesive.

[0049] Other exemplary embodiments of the step cover include a cap with a different shaped front, such as, for example, a flat front instead of curved.

[0050] The present invention is an improvement over existing technologies due to the superior strength of the step cover when installed on the step. The present invention also provides for a way to create stair covers containing almost any decorative finish design desired. The decorative film, paper, or laminate on the cap(s), tread, and step cover riser can be original works or they can be digitally created copies of flooring products (real wood or products made to look like wood or stone and the like) so that they match the flooring.

[0051] The tread and the step riser cover can be made from a variety of materials including real wood, fiberboard and/or particle board.

[0052] The desired decorative finish is printed onto paper or similar material that is coated with a topcoat and then wrapped onto the component parts of the stair cover for wear resistance.