Modular staircase and method of constructing same

Abstract

A modular staircase frame is lightweight, adjustable, and may be brought to a worksite in pieces to be assembled. The modular staircase frame includes two opposing sets of laterally spaced blades, which may be adjustably connected to form laterally spaced ascending frame members. The opposing sets of blades may include a first pair of blades and a final pair of blades to anchor the frame to a first and second surface, respectively. The blades have openings for adjustable attachment of adjacent blades. The frame may also include stiffeners for added structural support. The opposing sets of laterally spaced blades may further include one or more corner blades for changing the direction of the staircase. Once the frame is installed, treads (temporary or final) can be removably installed on the frame to create a staircase.

Claims

1. A modular staircase frame for supporting removable treads in the construction of a staircase, the modular staircase frame comprising: two opposing sets of laterally spaced blades, each of the two opposing sets of laterally spaced blades comprising a plurality of adjacent blades, each of the plurality of adjacent blades defining a plurality of spaced apart openings, each of the plurality of adjacent blades being adjustably connected to a connecting blade for connecting two of said plurality of adjacent blades, each of the connecting blades defining plurality of spaced apart openings for overlapping the plurality of spaced apart openings defined by the plurality of adjacent blades, the connecting blades being adjustably connected to the plurality of adjacent blades by a fastener received through the spaced apart openings of the plurality of adjacent blades and the connecting blades, the plurality of adjacent blades being connected by the connecting blades to define an adjustably spaced ascending formation relative to a proximate adjacent blade, said two opposing sets of laterally spaced blades defining two laterally spaced ascending frame members, said two opposing sets of laterally spaced blades including a first pair of opposing laterally spaced blades each defining a flange extending laterally therefrom for anchoring said first pair of opposing laterally spaced blades to a first surface, and a final pair of opposing laterally spaced blades remote from the first pair of opposing laterally spaced blades, each of said final pair of opposing laterally spaced blades defining a flange extending laterally therefrom for anchoring said final pair of opposing laterally spaced blades to a second surface, the modular staircase frame further comprising at least one stiffener extending between the two opposing sets of laterally spaced blades, said at least one stiffener comprising two slidably connected overlapping panel members, each of said overlapping panel members defining a longitudinal groove, the longitudinal grooves of the overlapping panel members overlapping for receiving a fastener through said overlapping groove, whereby the overlapping panel members are movable between a plurality of intermediate positions for adjusting the length of the at least one stiffener, the at least one stiffener including a fastener for fastening the two overlapping panel members at a selected one of said plurality of intermediate positions.

2. The modular staircase frame of claim 1, wherein the modular staircase frame is assembled at a worksite.

3. The modular staircase frame of claim 1, wherein the plurality of adjacent blades are made of a material selected from the group consisting of aluminum, PVC, fiberglass, carbon fiber, plexiglass, polycarbonate, aluminum alloys, and titanium.

4. The modular staircase frame of claim 1, wherein each of the two opposing sets of laterally spaced blades further comprises at least one corner blade.

5. The modular staircase frame of claim 1, wherein the plurality of adjacent blades each define at least one flange for supporting a removable tread.

6. A method of constructing a modular staircase frame for supporting removable treads in the construction of a staircase, the method comprising: arranging two opposing sets of laterally spaced blades, the arranging step being practiced such that: each of the two opposing sets of laterally spaced blades comprising a plurality of adjacent blades, each of the adjacent blades defining a plurality of spaced apart openings, each of the adjacent blades being adjustably connected to a connecting blade for connecting two of said adjacent blades, each of the connecting blades defining a plurality of spaced apart openings for overlapping the spaced apart openings defined by the adjacent blades, the connecting blades being adjustably connected to the adjacent blades by a fastener received through the spaced apart openings of the adjacent blades and the connecting blades, the two opposing sets of laterally spaced blades connected by the connecting blades further including a first pair of opposing laterally spaced blades and a final pair of opposing laterally spaced blades remote from the first pair of opposing laterally spaced blades, to define two laterally spaced ascending frame members; anchoring the first pair of opposing laterally spaced blades to a first surface; anchoring the final pair of opposing laterally spaced blades to a second surface; adjustably connecting each of said plurality of adjacent blades with one of said connecting blades to define an ascending formation relative to an adjacent blade; and removably securing at least one stiffener between the two opposing sets of laterally spaced blades, said at least one stiffener comprising two slidably connected overlapping panel members, each said overlapping panel members defining a longitudinal groove, the longitudinal grooves of the overlapping panel members overlapping for receiving a fastener through said overlapping groove, whereby the overlapping panel members are movable between a plurality of intermediate positions for adjusting the length of the least one stiffener, the at least one stiffener including a fastener for fastening the two overlapping panel members at a selected one of said plurality of intermediate positions.

7. The method of claim 6, wherein the method is carried out at a worksite.

8. The method of claim 6, further comprising adjusting the length of the at least one stiffener to define the spacing between the two opposing sets of laterally spaced blades.

9. The method of claim 6, wherein each of the two opposing sets of laterally spaced blades further comprises at least one corner blade.

10. The method of claim 6, wherein the plurality of adjacent blades each define at least one flange extending laterally therefrom for supporting a removable tread.

Description

DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of the modular staircase frame assembled in accordance with an embodiment of the disclosure.

(2) FIG. 2 is a perspective view of the modular staircase frame of FIG. 1 with removable treads and cladding.

(3) FIG. 3 is a side elevational view of a blade in accordance with an embodiment of the disclosure.

(4) FIG. 4 is a side elevational view of a connecting blade in accordance with an embodiment of the disclosure.

(5) FIG. 5 is a perspective view of a portion of the modular staircase frame assembled in accordance with an alternative embodiment of the disclosure.

(6) FIG. 6 is a front elevational view of the modular staircase frame shown in FIG. 5.

(7) FIG. 7 is a perspective view of the modular staircase frame of FIGS. 5 and 6 with removable treads and risers attached.

DETAILED DESCRIPTION

(8) The present disclosure relates to a modular staircase frame and method of constructing same. The modular staircase frame is lightweight, adjustable, and may be brought to a worksite in pieces to be assembled. The modular staircase frame is comprised of two opposing sets of laterally spaced blades, which may be adjustably connected to form laterally spaced ascending frame members. The opposing sets of blades may comprise a first pair of blades and a final pair of blades to anchor the frame to a first and second surface, respectively. The blades comprise openings for adjustable attachment of adjacent blades. The frame may also comprise stiffeners for added structural support. The opposing sets of laterally spaced blades may further comprise one or more corner blades for changing the direction of the staircase. Once the frame is installed, treads (temporary or final) can be removably installed on the frame to create a staircase.

(9) Referring to FIG. 1, a modular staircase frame 1 is provided in assembled form. Although the frame 1 is shown in assembled form, individual components of the frame 1 may be packaged together or separately for assembly at a worksite, which may include a building site, a house either during construction or after construction has been completed, or any other site where a staircase may be installed. Due to the modular and adjustable nature of the frame 1, as described herein, the same components may be used regardless of the distance between floors being connected by the staircase, and regardless of the desired step height, length, and width.

(10) The frame 1 comprises two opposing sets of laterally spaced blades 20, 22. Each set of laterally spaced blades comprises a plurality of adjacent blades 2 adjustably connected together in an ascending formation. The two opposing sets of laterally spaced blades 20, 22 form the laterally spaced ascending frame members of the modular staircase frame 1. At one end of the two opposing sets of laterally spaced blades 20, 22, there is a first pair of opposing laterally spaced blades 23. Remote from the first pair of opposing laterally spaced blades 23, there is a final pair of opposing laterally spaced blades 10.

(11) As may be seen in FIG. 1, each of the first pair of opposing laterally spaced blades 23 defines a flange 8 for anchoring the first pair of opposing laterally spaced blades 23 to a first surface 9. The flange 8 may be integrally formed with each of the first pair of opposing laterally spaced blades 23, or it may be separately joined. In a preferred embodiment, the first surface 9 may be a horizontal floor, but the skilled person will appreciate that the first surface 9 may be any surface to which a staircase frame could be anchored.

(12) Likewise, each of the final pair of opposing laterally spaced blades 10 defines a flange 26 for anchoring the final pair of opposing laterally spaced blades 10 to a second surface 11. The flange 26 may be integrally formed with each of the final pair of opposing laterally spaced blades 10, or it may be separately joined. In a preferred embodiment, the second surface 11 may be a vertical wall, but the skilled person will appreciate that the second surface 11 may be any surface to which a staircase frame could be anchored.

(13) In a preferred embodiment, the blades 2, 10, and 23 may be made of aluminum, PVC, fiberglass, carbon fiber, plexiglass, polycarbonate, aluminum alloys, or titanium. In a less preferred embodiment, the blades 2, 10, and 23 may be made of steel. In a preferred embodiment, the blades, 2, 10, and 23 are at least ⅜″ thick. The blades 2, 10, and 23 may also be symmetrical, so that the same blade could be used for either side of the pair of blades.

(14) Since the two opposing sets of laterally spaced blades 20, 22 form the laterally spaced ascending frame members of the modular staircase frame 1, there is no need to use additional external structural elements, such as stringers or a wall, to support the staircase beyond the frame 1. Accordingly, the modular staircase frame 1 may be used to support a freestanding staircase.

(15) In one embodiment, the two opposing sets of laterally spaced blades 20, 22 may also comprise a plurality of connecting blades 12. These may be interposed between the blades 2 to provide greater adjustability when connecting adjacent blades 2 together, as described below.

(16) As shown in FIGS. 3 and 4, each of the blades 2 and connecting blades 12 have a plurality of spaced apart openings 3 that are adapted to receive a fastener 18. Each of the first pair of opposing laterally spaced blades 23 and the final pair of opposing laterally spaced blades 10 also have a plurality of spaced apart openings 3 that are adapted to receive a fastener 18. The openings 3 may be in the form of holes or channels, as shown in FIG. 5 with reference to corner blade 19.

(17) Due to the number and spacing of the openings 3, adjacent blades 2 may be adjustably attached to each other by selecting the desired opening 3 on each adjacent blade 2 through which the fastener 18 may be inserted, in order to vary the height and distance between adjacent blades 2. Once the appropriate opening 3 is selected on adjacent blades, the openings 3 are aligned and a fastener 18 is removably inserted through the aligned openings 3 to fix the adjacent blades in place in an ascending formation at a desired height and distance. Multiple fasteners 18 may be used to provide added stability to the frame 1.

(18) The modular staircase frame 1 may also comprise stiffeners 6 for added structural support. The blades 2 may have a stiffener fastening portion 4, and the stiffeners 6 may be removably fastened to the blades 2 at the stiffener fastening portion 4. The stiffeners 6 may be fastened to a single pair of blades 2, or to each pair of blades 2, but are preferably fastened to at least every other pair of blades 2, as shown in FIG. 1.

(19) The stiffeners 6 may be of fixed length, but are preferably of adjustable length to vary the spacing between the two opposing sets of laterally spaced blades 20, 22. The stiffeners 6 may comprise a pin-in-slot system to vary the length of the stiffeners 6 and fix them at a preferred length.

(20) As shown in FIG. 1, the blades 2, 10, and 23 may also define a flange 7 for supporting a removable tread, which may be a first end step 14, final end step (not shown), or intermediate step 16. The flange 7 may be integrally formed with the blade 2, 10, and 23, or it may be separately joined.

(21) In the embodiment where the flange 7 is separately joined, it may be a bracket, which may be removably fastened to the bracket fastening portion 5 of the blades 2, 10, and 23. Preferably, at least one bracket is fastened to each blade 2, 10, and 23. More preferably, two brackets are fastened to each blade 2, 10, and 23 at a spaced apart distance to support and removably join the tread to the blade. The brackets may be made of any suitable material, and are preferably ⅛″ to ¼″ thick.

(22) Since the treads may be removably fastened to the flanges 7, or removably secured to the blades 2, 10, and 23 (including by cutting notches into the treads), a set of temporary treads may be installed while a house is still under construction, to avoid damage to the final set of treads.

(23) The two opposing sets of laterally spaced blades 20, 22 are placed at a lateral distance from each other that may be selected by the user. In the embodiment shown in FIGS. 1 and 2, the lateral distance between the two opposing sets of laterally spaced blades 20, 22 is substantially equivalent to the width of the treads resting on the modular staircase frame 1.

(24) In an alternative embodiment, the two opposing sets of laterally spaced blades 20, 22 may be placed close together, preferably at least 6″ apart, in a “monolith” construction. In this alternative embodiment, the treads overhang the two opposing sets of laterally spaced blades 20, 22.

(25) Depending on the aesthetic preference of the user, a staircase may also have risers 17 and additional cladding 13, which may cover the outside (shown in FIG. 2) and bottom (not shown) of the modular staircase frame 1.

(26) The embodiment shown in FIG. 1 is a straight staircase between two floors. The present disclosure also contemplates a staircase that takes one or more turns. In the embodiment shown in FIGS. 5-7, each of the two opposing sets of laterally spaced blades 20, 22 further comprises at least one corner blade 19. The corner blade 19 connects two adjacent blades 2 around a turn that is preferably 90 degrees, but may be any suitable angle. The corner blades 19 and adjacent blades 2 may support two or more winder steps (as shown in FIG. 7), or a single landing.

(27) The present disclosure also contemplates a method of construction of a modular staircase frame 1. As set out above, the modular staircase frame 1 comprises two opposing sets of laterally spaced blades 20, 22. In order to create the two opposing sets of laterally spaced blades 20, 22, a plurality of adjacent blades 2 are arranged in an ascending formation.

(28) The first pair of opposing laterally spaced blades 23, each of which define a flange 8, are anchored to a first surface 9. Similarly, the final pair of opposing laterally spaced blades 10, each of which define a flange 26, are anchored to a second surface 11. The anchoring may be done using fasteners, or any other known method of anchoring a staircase frame to a surface.

(29) Each adjacent blade 2, 10, and 23 is adjustably connected together in the manner described above to form the two laterally spaced ascending frame members of the modular staircase frame 1.

(30) Although the invention has been described with reference to illustrative embodiments, it is to be understood that the invention is not limited to these precise embodiments. Numerous modifications, variations, and adaptations may be made to the particular embodiments of the invention described above without departing from the scope of the invention. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

(31) Immaterial modifications may be made to the embodiments described herein without departing from what is covered by the claims. The indefinite article “a” before a claim feature does not exclude more than one of the feature being present. Each of the individual features described here may be used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the claims.