STAIR STRINGER ASSEMBLY, SYSTEM, AND METHOD

Abstract

A bilateral bracket for steps to be fixed on a stringer having a number of steps and risers, the bilateral bracket having a generally flat body defining a framing edge having a riser edge and a tread edge; the riser edge having a riser flange perpendicularly extending therefrom in a first direction; the tread edge having a tread flange perpendicularly extending therefrom in the first direction, wherein the tread extends between a distal end and a proximal end; the framing edge defining an acute angle relative to each other, wherein the flat body does not project beyond a profile defined by the distal and proximal ends inward of a profile defined by the framing edge; and a stringer edge along the body, opposite the framing edge, wherein the stringer edge has an array of holes for selectively attaching to either side of the stringer.

Claims

1. A bilateral bracket for steps to be fixed on a stringer having a number of steps and risers, the bilateral bracket comprising: a generally flat body defining a framing edge having a riser edge and a tread edge; the riser edge having a riser flange perpendicularly extending therefrom in a first direction; the tread edge having a tread flange perpendicularly extending therefrom in the first direction, wherein the tread extends between a distal end and a proximal end; the riser and tread edges defining an acute angle relative to each other, wherein the flat body does not project beyond a profile defined between two lines orthogonally drawn from each of the distal and proximal ends; and a stringer edge along the body, opposite the framing edge, wherein the stringer edge has an array of holes for selectively attaching to either side of the stringer in one of a plurality of orientations so as to adjust an elevation of the tread edge relative to said stringer.

2. The bilateral bracket of claim 1, wherein the array of holes comprises two rows of holes.

3. The bilateral bracket of claim 2, wherein adjacent holes of each row of holes are approximately one inch apart.

4. The bilateral bracket of claim 2, wherein the row of the two rows of holes that is closer to the tread flange is along a line orthogonal relative to a distal end of the tread flange so that when folded along said row a bent flange is form substantially parallel to the tread flange, and wherein the bent flange circumscribes the other row of the two rows of holes, whereby the bent flange provides an anchor for a bottom step.

5. A method of installing the bilateral bracket of claim 1, the method comprising: affixing a framing square to a 2×; defining an orientation of the bilateral bracket relative to the 2× as a function of a riser value and a tread value for the number of steps and risers; and clamping the bilateral bracket to the framing square prior to attaching the stringer edge to the 2×.

6. The method of claim 5, wherein a majority of the tread flange engages a first leg of the framing square during attachment of the bilateral bracket to the stringer.

7. The method of claim 6, wherein a distal end of the riser flange engages a second leg of the framing square during attachment of the bilateral bracket to the stringer.

8. The method of claim 6, further comprising marking along edges of the first and second legs of the framing square along a face of the 2×.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0046] FIG. 1 is a top perspective view of three spaced-apart stringers of an exemplary embodiment of the present invention, shown in use.

[0047] FIG. 2 is a detailed perspective view of an exemplary embodiment of an end 16 (or “the return”) of a bracket of the present invention.

[0048] FIG. 3 is a top perspective view of an exemplary embodiment of a bracket of the present invention, note that the riser flange 14 and the tread flange 15 run continuously to the intersection and there is no change in the metal folding (i.e., there is no lap at the flange intersection—they meet and end—one does not lap on to the other).

[0049] FIG. 4 is a perspective view of an exemplary embodiment of the bracket of the present invention.

[0050] FIG. 5 is a perspective view of an exemplary embodiment of the present invention, illustrating using the framing square 20 to mark up a 2×, wherein the marks riser and tread marks 44, 45 are projected onto the edges of the other 2×s for the same square, as illustrated in FIG. 6. These riser and tread marks 44, 45 are critical in building a matching set of stringers since they locate the precise placement of the metal connectors. Marking the edge makes using either face of the 2× member 60 easier (because of the bilateral applicability of the present invention). Slight extensions at each end are needed to catch the framing square so trimming the ends comes later. The square stops 21 may be fixed to the framing square 20 to facilitate the proper alignment against the edge of the 2× member 60 to “set” the framing square 20 to a seven-inch riser and a ten and half inch tread dimension pursuant the comfort formula of the riser+tread equals approximately seventeen and one-half of an inch. Once set to the proper alignment, the user can mark a pattern with the riser and tread marks 44, 45. This spaced apart pattern of two marks (one for the riser and the other for the tread) can be repeated along the length of the 2× member (even though only one pair is shown in FIGS. 5 and 6).

[0051] FIG. 6 is a top perspective view of an exemplary embodiment of the present invention, illustrating the projected markings 64 that are projected along a plurality of 2× members 60 by way of a straight edge and marker. Note, the riser height, minus the tread thickness, determines a line parallel to the tread mounting surface. It is marked on the fixture and 2×. This line represents a bend required in the fixture and a cut on the 2×. It also defines the stringer contact with the floor or landing.

[0052] FIG. 7 is a top plan view of an exemplary embodiment of the present invention, showing a clamp 30 holding the stair bracket 10 firmly against the framing square 20 wherein the connector is fastened by two nails or screws prior to releasing the clamp 30. Then more fasteners may be added. A clamp 30 may also be used to hold the connector to the 2× member 60 to free both hands. The installation tool/framing square 20 repeatedly determines the exact riser and tread exposure, and the marks locate the steps to match other stringers having the same marks. The framing square 20 clamped to the bracket 10 is now set to align with the original (framing square 20—see FIG. 5) riser and tread marks 14 and 15 of the 2× member 60. Spring clamps 30 may speed this procedure. With the bracket 10 fixed to the properly re-located framing square 20, the bracket 10 can be directly connected to the 2× member 60. The framing square 20 can be removed (via releasing the clamp 30) so that the remaining fasteners can fix the bracket 10 to the 2× member 60.

[0053] FIG. 8A is a top plan view of an exemplary embodiment of the present invention. There is a small slit in the metal that this detail shows. It is intended to allow the flange to pull away and permit a flexible tab that adapts to the riser board being a small distance from the flange on any riser greater than 6″. This only occurs on the inclined riser model.

[0054] FIG. 8B is a detailed view of an exemplary embodiment of a flange of the present invention.

[0055] FIG. 9 is a perspective view of an exemplary embodiment of the present invention illustrating a bent flange formed along the generally flat body of the stair bracket/fixture 10, wherein a fold lines is aided by an upper row of two rows of holes along the stringer portion of the stair bracket 10.

DETAILED DESCRIPTION OF THE INVENTION

[0056] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

[0057] Referring now to FIGS. 1 through 9, the present invention may include a stair stringer assembly, system, and method.

[0058] The shape components or stair bracket attaches in multiples to a 2×4 or 2×6 to form a stair stringer. This metal-wood fabrication is intended to replace the conventional method of butchered 2×12 stringers. A battery powered screwdriver replaces the circular saw to attach identical shapes that are the result of CNC (computerized numerical control) technology.

[0059] There are two components of the stair bracket: a typical vertical riser and an inclined riser with a nosing are featured. One simple component works on the left or right side and configures to the unique bottom step situation. The bottom step is unique because it has the only riser that is reduced to account for the tread thickness, enabling a metal floor connector that anchors each stringer.

[0060] At the heart of the metal shape component system is the framing square being used as an installation tool. Placing shapes accurately on a 2× requires using the framing square. At least one clamp is required and the square needs stair gauges.

[0061] Stair construction requires making several identical stringers that need to align in supporting the treads and risers. This requirement of precision is met by metal shapes that are formed by the close tolerances of a manufactured product which easily exceeds the result on-site built stringers.

[0062] Now that the shapes match, they must also be placed on the 2×s in a uniform and equally spaced sequence. The objective is to be aligned with the corresponding shapes on the adjacent stringers. The initial procedure of a pattern layout and edge marking ensures that this happens.

[0063] Basically, metal shape use can exceed conventional methods in having more identical step dimensions and form and they can match the stringer arrangement by mimicking the pattern technique. Both systems use the same technique to ensure that each step aligns with its respective mates of the same step. And the framing square is involved in both techniques.

[0064] The step-shaped metal components are designed to be clamped onto a framing square and the stair gauge setting determines placement on a 2× in a repetitive and precise fashion. Setting the stair gauges one time on the square for this procedure is better than reading two scales on a single shape installation.

[0065] On the inclined riser version, a cut exists near the bottom of the flange on the inclined riser version of the shape component. The intent is to allow the bottom flange to break away in the likely event that a riser greater than 6″ is selected. In selecting a riser greater than 6″ the board will not fit against the metal flange and by allowing the flange to break away a flexible tab is formed to secure the bottom of the riser. If an 8″ riser is selected a space of about 3/16″ exists between the flange and the riser board and this is the maximum situation. A hole is placed very near the flange end and it is expected that the second hole would be used in a 6″ riser to avoid splitting.

[0066] The screws placed near the top of the flange have a reduced space between the flange and the board, relative to the bottom, and adhesive thickness compensates to close this differential. This issue is the result of making a shape that is adjustable where the nosing remains 1⅛″ and the riser height varies, which is to say the angle of inclination varies to meet the ideal nosing dimension.

Framing Square Installs Step-Shaped Components in Stair Stringer Assembly

[0067] The shapes are attached to a 2× in multiples and a single form works for both right and left and bottom step applications. Building codes require that all risers in a stair be equal in height and shapes adjust to any riser between 6″ and 8″. There is a shape for standard vertical risers and a shape for inclined risers that includes a nosing. The galvanized sheet metal material is intended for interior and exterior use. Screws and supplemental adhesives secure the metal flange to the treads and risers and fasteners are hidden and applied from the rear or underside of the stair. A continuous separate line of holes 18 (in some embodiments, the lines are spaced apart by approximately one inch on center) which enables keying the adhesive to the flange.

[0068] Using a framing square to place the shapes is more accurate than ruler tabs of tiny increments or hole clusters that other metal shapes feature. Stair construction requires precision stringers that align when placed side by side. Using shapes that are plasma cut and CNC manufactured easily exceed the tolerances of an on-site cut 2×12 stringer. Mimicking the pattern layout on the component 2×s, just as a conventional stair builder uses a cut stringer as a pattern to mark other 2×s intended for the same stair, ensures that the component stringers align.

[0069] The riser height and tread thickness selected determines the bottom shape configuration and it is bent to form a bracket to anchor the stringer to the floor. This adaptation to a problematic issue, caused by dissimilar riser heights combined with various tread thicknesses, permits a single shape form to meet the requirements of almost all wood-based stairs. Adjusting to common riser and tread dimensions, providing equal riser heights, and bending to configure an anchor bracket for each stringer is characteristic of the metal shape function.

[0070] Metal shapes easily adjust to any riser between 6″ and 8″ and corresponding tread selections. The shapes easily work in left or right-side applications. However, to use that same shape in the bottom step application it must be configured or bent to create a bracket that serves to anchor the stringer to the floor.

[0071] Replacing the traditional multifaceted wood stringer with a smooth member having metal appendages reduces combustible material in a critical circulation area in the event of a fire. This aspect is additional safety to a system that has eliminated the cutting of stringers. To wit, the extensive cutting of large dimension lumber into giant sawtooth forms increases the ignition potential compared to a smooth or beam-like member.

[0072] Sheet metal is used to form a step shaped fixture that functions in right or left mountings. Both are necessary to facilitate hidden fasteners (screws) being applied from the back or under side of stair. Adhesive is also applied to the row of screws not used for mechanical fastening. The row of holes key the glue to the fixture for a secure bond. Two rows exist on each riser and tread flange to allow this to take place. The metal fixtures are adjustable and may be removed to correct errors. Adjustable is necessary because a safe stair has equal riser heights (a code requirement).

[0073] Each stair bracket 10 is bilateral and a single shape functions to work in left and right applications. There are no scale tabs and a framing square 20 is used to install the shapes. This is a more precise method and reduces the chance of error such as misreading a scale of which there are many in the typical stair.

[0074] The stair bracket 10 is bent and configured to the unique bottom steps by forming an anchor bracket, as shown in FIG. 7, to secure each stringer to the floor. A typical vertical riser model and an inclined riser with a nosing model are proposed. Both install using the framing square. Two rows of holes 12 exist on the tread and riser flanges. One is for screws and the other keys a bead of adhesive to the metal flange.

[0075] The framing square 20 is common to construction sites and a stair craftsman uses one to layout a stair stringer 50 which becomes a pattern for marking other members intended for the same stair. Small stair gauges clamp to the square and reflect riser and tread selections. This same setup is used to layout and install metal shapes. Framing square 20 is used in a preliminary procedure of laying out a pattern and using it to mark other members for the same stair.

[0076] A method of using the invention may include the following. In building a stair, the risers and treads should be identical, and the stringers should match. Marking the 2×s member 60, as illustrated in FIG. 5, and using the framing square 20 to place the connectors will produce the desired result. Use a 2× to firmly set the stair gauges on the framing square to the riser and tread values.

[0077] Referring to FIG. 6, the marks are projected onto the edges of other 2×s for the same stair. These marks are critical in building a matching set of stringers since they locate the precise placement of the metal connectors. Marking the edge makes using either face of the 2×s easier. Slight extensions at each end are needed to catch the framing square so trimming the ends comes later.

[0078] Referring to FIG. 7, the square acts as an installation tool for the connectors. A clamp holds the metal connector firmly against the square and the connector is fastened by a plurality of nails or screws prior to releasing the clamp. Then more fasteners may be added. A clamp may also be used to hold the connector to the 2× to free both hands.

[0079] The installation tool 20, again, repeatedly determines the exact riser and tread exposure and the marks locate the steps to match other stringers having the same marks. The square setting that is the origin of the marks is now placing a connector within the marks. The bottom of the stringer requires special attention. Attach the bottom connector with two fasteners and mark the 2× and the connector for cutting. Check that trimming the 2× will not delete the screw holes, then remove the two fasteners.

[0080] Trim and form the connector to create a bracket to act as a floor anchor (exterior connector protrusions may be embedded in concrete or formed to anchor to a landing). Install the bottom connector using previously made holes.

[0081] Mark and trim the top of the stringer. Use this stringer as a pattern to trim the top and bottom of others on the same stair.

[0082] As a precaution, choose a 2× to have connectors mounted on the opposite side and mark “XX's” on the side you wish to avoid. The connectors are mounted on the inside face of an end-of-tread stringer. This facilitates riser and tread attachment and reduces the thickness of blocking at walls. (The stringer is spaced, blocked, away from the wall studs to allow finish material and a skirt board to go behind the sawtooth stair shape, and protect the finish wall surface from foot traffic and cleaning tool damage). Now finish the remaining stringers in a similar fashion.

[0083] Temporary treads may be used to avoid damage to the finished material. Use adhesive and screws to fasten the finished material to the connectors. Apply a bead of adhesive over the line of holes not intended for screws on each connector.

[0084] The metal connectors are without markings that would locate their placement and depend on the square installation tool to locate their placement. This feature ensures precision placement each time. The installer is not reading a scale with numbers or selecting a hole from a cluster of holes.

[0085] Metal fixtures are noncombustible material replacing combustible material in an area used to escape a burning building.

[0086] A step shaped metal appendage, adjustable and calibration impaired, concealed fastening and bilateral, uses the lowly framing square as an installation tool to add speed, safety and fire resistance to fabricating stair stringers.

[0087] Sporting an inclined riser model, with a mandated safety nosing, and a traditional vertical riser version, the galvanized steel product can create a modernist wood interior stair and an exterior deck stair. Both have concealed fasteners and employ screws and adhesive in assembly and eliminate the need for large dimension lumber for building stair stringers. Both treads and risers use hidden fasteners for a blemish free furniture grade finish. Mounting holes at 1″ spacing invite prefinished flooring to be used and the wood varieties are numerous and exotic.

[0088] As used in this application, the term “about” or “approximately” refers to a range of values within plus or minus 10% of the specified number. And the term “substantially” refers to up to 80% or more of an entirety. Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated, and each separate value within such a range is incorporated into the specification as if it were individually recited herein.

[0089] For purposes of this disclosure, the term “aligned” means parallel, substantially parallel, or forming an angle of less than 35.0 degrees. For purposes of this disclosure, the term “transverse” means perpendicular, substantially perpendicular, or forming an angle between 55.0 and 125.0 degrees. Also, for purposes of this disclosure, the term “length” means the longest dimension of an object. Also, for purposes of this disclosure, the term “width” means the dimension of an object from side to side. For the purposes of this disclosure, the term “above” generally means superjacent, substantially superjacent, or higher than another object although not directly overlying the object. Further, for purposes of this disclosure, the term “mechanical communication” generally refers to components being in direct physical contact with each other or being in indirect physical contact with each other where movement of one component affect the position of the other.

[0090] The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the embodiments or the claims. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the disclosed embodiments.

[0091] In the following description, it is understood that terms such as “first,” “second,” “top,” “bottom,” “up,” “down,” and the like, are words of convenience and are not to be construed as limiting terms unless specifically stated to the contrary.

[0092] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.