HIDDEN CONSTRUCTION BRACKET AND RELATED METHOD
20200217077 ยท 2020-07-09
Inventors
Cpc classification
International classification
Abstract
A bracket and related method to construct stairways is provided. The bracket includes a top horizontal leg having a first width and a first spacer of a first dimension and a second spacer of a smaller second dimension, and a vertical leg joined with the top leg, the vertical leg having a first height, with a ratio of the first width to the first height being at least 1:2. The method can include placing the top leg adjacent an underside of stair boards, selectively altering or not altering the first spacer based on a preselected gap between the boards, fastening the top leg to the underside of the boards with fasteners while the first spacer and/or the second spacer maintains the preselected gap, placing the bracket vertical leg adjacent a stringer, and fastening the vertical leg to the stringer, optionally while the installer remains above the stairway and stringer.
Claims
1. A method of assembling a stairway, the method comprising: providing a bracket having a top horizontal leg having a first width and a first spacer of a first dimension and a second spacer of a second dimension smaller than the first dimension, the top horizontal leg defining at least two fastener holes, the bracket having a vertical leg joined with the top horizontal leg, the vertical leg defining at least two fastener holes, the vertical leg having a first height, the ratio of the first width to the first height being at least 1:2; marking an underside of a first stair board and a second stair board with a marker line along a stringer adjacent the first and second stair boards; turning the first stair board and the second stair board over and positioning the top horizontal leg parallel to the marker line; selectively altering or not altering the first spacer based on a preselected gap between the first board and the second board; fastening the top horizontal leg to the underside of the first stair board with a first fastener and a second fastener; fastening the top horizontal leg to the underside of the second stair board with a third fastener and a fourth fastener, while at least one of the first spacer and the second spacer maintains the preselected gap; turning the first board and second board over with the bracket attached thereto; placing the vertical leg of the bracket adjacent the stringer; and fastening the vertical leg to the stringer with a fifth fastener and a sixth fastener with a tool, whereby a user operating the tool is able to remain substantially above the stringer while operating the tool, rather than position a body of the user substantially under the stringer, the first board and the second board.
2. The method of claim 1, wherein the preselected gap is smaller than the first dimension, wherein the selectively altering or not altering the first spacer includes altering the first spacer so that the first spacer is not disposed between the first stair board and the second stair board.
3. The method of claim 2, wherein the second spacer is disposed between the first board and the second board, engaging side surfaces of each of the first board and the second board, to set the preselected gap between the first stair board and the second stair board, the preselected gap corresponding to the smaller second dimension.
4. The method of claim 2, wherein the altering the first spacer includes removing the first spacer from the bracket.
5. The method of claim 4, wherein the removing the first spacer from the bracket includes breaking the first spacer off the top horizontal leg.
6. The method of claim 1, wherein the tool is a power tool, wherein the power tool includes a longitudinal drive axis, wherein the longitudinal drive axis is substantially parallel to a longitudinal axis of the first board during the fastening.
7. The method of claim 1, wherein a bottom of the vertical leg includes a bevel, wherein the bevel engages the stringer to guide the bracket into position adjacent the stringer.
8. The method of claim 1, wherein the first, second, third and fourth fasteners all remain fixedly secured to the top horizontal leg before any of the first, second third and fourth fasteners are advanced during the fastening step, wherein the fifth and sixth fasteners all remain fixedly secured to the vertical leg before any of the fifth and sixth fasteners are advanced during the fastening step.
9. A method of assembling a stairway, the method comprising: providing a bracket including a top horizontal leg having a first width and a first spacer of a first dimension and a second spacer of a second dimension smaller than the first dimension, the top horizontal leg defining at least two fastener holes, the bracket having a vertical leg joined with the top horizontal leg, the vertical leg having a first height; placing the top horizontal leg adjacent an underside of a first and a second stair board; selectively altering or not altering the first spacer based on a preselected gap between the first stair board and the second stair board; fastening the top horizontal leg to the underside of the first stair board and the second stair board with a plurality of fasteners while at least one of the first spacer and the second spacer maintains the preselected gap; turning the first stair board and second stair board over with the bracket attached thereto; placing the vertical leg of the bracket adjacent a stringer; and fastening the vertical leg to the stringer with a plurality of fasteners with a tool, whereby a user operating the tool is able to remain substantially above the stringer while operating the tool, rather than position a body of the user substantially under the stringer, the first stair board and the second stair board.
10. The method of claim 9 comprising: wherein the preselected gap is smaller than the first dimension, wherein the selectively altering or not altering the first spacer includes altering the first spacer so that the first spacer is not disposed between the first stair board and the second stair board.
11. The method of claim 10, wherein the second spacer is disposed between the first stair board and the second stair board to set the preselected gap between the first stair board and the second stair board, the preselected gap corresponding to the second smaller dimension.
12. The method of claim 10, wherein the altering the first spacer includes breaking the first spacer of from the bracket, the bracket being constructed from a polymeric material.
13. The method of claim 9, wherein the first dimension is inch and the second dimension is less than inch.
14. The method of claim 13, wherein the first spacer is cylindrical and the second spacer is cylindrical, wherein the first spacer and the second spacer are positioned adjacent a first side surface of the first stair board and a second side surface of the second stair board after the fastening step, wherein the first spacer and the second spacer do not project beyond an upper surface of the first stair board after the fastening step.
15. The method of claim 9, wherein each of the plurality of fasteners are secured to and project from the respective top leg and vertical leg before the bracket is placed adjacent the first and second stair boards.
16. A stairway stringer bracket comprising: a top horizontal leg having a first width and a first spacer of a first dimension and a second spacer of a second dimension smaller than the first dimension, the top horizontal leg defining at least two fastener holes, a vertical leg joined with the top horizontal leg, the vertical leg having a first height, with a ratio of the first width to the first height being at least 1:2.
17. The stairway stringer bracket of claim 16 comprising: a first plurality of fasteners secured to and projecting from top horizontal leg, each of the fasteners having a plurality of threads visible adjacent a bottom surface of the top horizontal leg; and a second plurality of fasteners secured to and projecting from vertical leg, each of the fasteners having a plurality of threads visible adjacent a side surface of the vertical leg.
18. The stairway stringer bracket of claim 16, wherein the first width is between inch and 1 inch, inclusive, wherein the first height is between 1 inch and 2 inch, inclusive, wherein the first dimension and the second dimension are each between 1/32 inch and inch, inclusive.
19. The stairway stringer bracket of claim 17, wherein the first plurality of fasteners includes at least two fasteners laterally positioned to the left of the first spacer and at least two fasteners laterally positioned to the right of the first spacer, wherein the second plurality of fasteners includes at least three fasteners spaced along the vertical leg.
20. The stairway stringer bracket of claim 19, wherein each of the first plurality of fasteners include a first head, wherein each of the second plurality of fasteners are disposed below the first heads of the first plurality of fasteners.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DESCRIPTION OF THE CURRENT EMBODIMENTS
[0034] A current embodiment of the bracket is illustrated in
[0035] Further, in this disclosure, the bracket is described in connection with boards. As used herein, boards can include any type of elongated element that has a length greater than its width. Examples of boards can include wood boards, constructed from any type of wood, whether pressed wood and/or lumber, composite boards, polymeric boards, steel or metal studs, panels, sheets and other similar type construction elements.
[0036] Turning now to the construction of the bracket, as shown in
[0037] The top leg 20 can define a plurality of fastener holes that extend from the top leg contact surface 21 to the bottom surface 22, optionally through the top leg 20. An exemplary fastener hole 24 is shown in
[0038] In the embodiment shown in
[0039] The respective fasteners and fastener holes can be associated with wings or tabs 25 of the top vertical leg 20. This can reduce weight and allow the holes 24 and respective fasteners to be placed farther away from the vertical leg. These tabs 25 can extend outward from a body of the leg 20.
[0040] As mentioned above, and shown in
[0041] Further, the fasteners associated with the vertical leg, also referred to as the second plurality of fasteners, can extend from the vertical leg. Each of those fasteners can be at least partially disposed in the respective holes in the vertical leg. Thus, each of the fasteners can be configured so that some of the threads and part of the shaft of those respective fasteners are visible adjacent the outer or side surface 32 of the vertical leg. These fasteners can be installed at least partially in the respective holes defined by the vertical leg.
[0042] As shown in
[0043] Optionally, the top leg 20 and the vertical leg 30 can be configured so that the fasteners associated with the top leg, and the fasteners associated with the vertical leg, are in a particular orientation. For example, as shown in
[0044] Further optionally, the respective axes of the vertical fasteners in the top horizontal leg can be oriented in a particular manner. As shown in
[0045] With further reference to
[0046] As shown in
[0047] As mentioned above, the spacers can have different dimensions. These dimensions can be selected to correspond to a preselected gap between boards with which the bracket will be used as described below. In some cases, the first dimension and the second dimension can each be between 1/32 inch and inch, inclusive. Optionally, the first dimension can be inch or greater, and the second dimension can be less than inch. Further optionally, the first dimension can be a inch and the second dimension can be inch. Of course, other dimensions can be selected depending on the application and the spacing, that is the preselected gap G as described below.
[0048] With reference to
[0049] Each of the first 41 and second 42 spacers optionally can be integrally formed with the remainder of the bracket and the top horizontal leg. For example, the spacers and the bracket can be formed of a homogeneous polymeric material. Of course, the spacers and the remainder of the bracket can be constructed from other materials, such as composites, metals, and combinations thereof. Each of the respective spacers 41, 42 can be altered or not altered in a step of a process. For example, when altered, one or both of the spacers can be removable, bendable, breakable, foldable, retractable, or able to be modified so that they will not be disposed between boards when the bracket is attached to the boards. In some cases, a spacer can be broken off or bent, so as to not project between adjacent boards and thereby produce or set a gap between those boards. The larger first spacer can be altered so that only the smaller second spacer can project between boards to set the gap therebetween. When a particular spacer is not altered, it generally is not removed, bent, modified, broken off, retracted or otherwise modified.
[0050] Where a spacer is configured to be altered by breaking it off, the bracket can be constructed from a polymeric or other breakable or fracturable material. The polymeric material optionally can be weakened at a base 41B or 42B of a spacer. In some cases, the bases can be scored, perforated or have a hole or groove to enable them to be easily removed by a user. In use, none, one or two or more of the spacers can be removed from the bracket to set a particular spacing or gap G between boards. For example, where the first spacer 41 dimension D1 is inch and the second spacer 42 dimension D2 is inch, and a user wants to utilize a preselected gap G of inch, the user will snap, break and/or otherwise alter the first spacer so that the dimension D1 is not established between adjacent side surfaces of boards to which the bracket is connected as described below. Instead, the dimension D2 can be established therebetween to set the gap.
[0051] A method of using the bracket of the current embodiment will now be described with reference to
[0052] The bracket 10 however can simplify the overall process and allow the installer C to work with units of stair boards rather than individual stair boards. Further, those units of stair boards can have boards that are properly and consistently spaced from one another with a preselected gap G as described below. In addition, the installer or user C operating a tool, such as a power drill 105, is able to remain substantially above the stringer 101 while operating the tool, rather than position the user's body substantially under the stringer, the first board and/or the second board, in a space 107U under those elements. Thus, the user can be generally more comfortable than when installing a set of stair boards on a stringer in a conventional manner, in which the user would climb under the stringer and stair boards to install some other type of fasteners from below the stair boards.
[0053] Returning to method herein, a user or installer C can begin to build a stairway 108 by cutting multiple notches 107N in a stringer 107, for example, as shown in
[0054] The user C can cut the stair boards and place them preliminarily in a respective notch 107N and on the stringer 107. The user can take a marker, such as a pencil or other writing or marking utensil and mark a marker line ML by moving the marker along the stringer so that the marker leaves a marker line on the undersides 101U and 102U of the respective first and second boards along a line that is generally parallel to the side/vertical surface of the underlying stair stringer 107. Where there are more stringers, the user can mark additional marker lines to accommodate additional brackets.
[0055] The user can turn the boards over so that the undersides 101U and 102U are exposed as shown in
[0056] On the other hand, if the user desires a smaller gap G between the boards, where that gap G corresponds to the dimension D2 of the second spacer 42, the user will selectively alter the first spacer based on the preselected gap G between the first board and the second board. To selectively alter the first spacer, the user can remove, break, bend, fracture, retract, push, move, extend or otherwise modify the first spacer so that it is not placed between the side surfaces 1015 and 102S of the boards. Optionally, the first spacer can be removed from the bracket. Thus, with the first spacer not placed there, the surfaces 1015 and 102S of the boards can be moved closer to one another until they engage the outer surfaces or surface 42S of the second spacer 42. The second spacer 42 thus sets the gap G at the dimension D2. Of course, where additional spacers of different dimensions are additionally included with the bracket, a user can selectively alter or not alter a number of spacers until the dimension of a particular spacer is selected to set the gap G between the boards. Further, it will be appreciated that multiple brackets with multiple spacers can be utilized to set the gap uniformly from first ends of the first and second boards to second ends of the first and second boards.
[0057] With the bracket 10 so aligned, and the preselected gap G set by a respective spacer, the user can operate a tool 105, which optionally can be a rotary power tool such as a power drill with a drive attachment, and engage the respective vertical fasteners. In particular, the user can use the tool 105 to fasten the top horizontal leg 20 to the underside 101U of the first stair board 101 with a first fastener 51 and a second fastener 52 by rotating those fasteners so that they advance into the first board and until the heads of those fasteners engage the bottom surface 22 of the top leg 20. The user can fasten the top horizontal leg 20 to the underside 102U of the second stair board 102 with a third fastener 53 and the fourth fastener 54, which can be rotationally advanced in a manner similar to that of the first and second fasteners. It is to be noted that where the first, second, third and fourth fasteners are preinstalled and secured in place in the respective holes of the top leg 20, those fasteners do not need to be manually handled by user. Thus, they can be simply advanced easily and quickly into the respective boards with a tool.
[0058] With the bracket 10 joined with the first and second boards via the plurality of first fasteners 51, 52, 53 and 54, a user can install additional brackets to secure the boards. The bracket accordingly can set the preselected gap G between those boards via the respective spacer. Those boards then can be turned up in direction T so that the undersides 101U and 102U face downward, generally toward a ground surface.
[0059] With the boards 101 and 102 joined via one or more brackets 10, the user can then place the boards on the horizontal levels 107L of the notches 107N in the stringer 107. For example, the vertical leg 30 of the bracket can be placed adjacent the side surface 107S of the stringer 107. Optionally, as the bracket 10 is so placed, the bevel 30B optionally can engage the corner 107C of the stringer and can guide the vertical leg 30 smoothly over that corner so that the remainder of the vertical leg, in particular the inner contact surface 31, can contact and/or can be placed adjacent the surface 107S of the stringer 107. This alignment and placement of the vertical leg and boards over the level 107L of the stringer 107 can be repeated for multiple brackets and multiple associated stringers of the stairway 108. It will be noted that during this placement of the bracket, the bracket, the first board and the second board remain connected as a single piece unit that can be easily moved and manipulated by the user C. Thus, the user C need not fumble with placing multiple stair boards and then fastening each individual stair board to the stringer. The bracket makes this possible, all while maintaining the preselected gap G between the first and second boards.
[0060] With the vertical leg 30 so placed beside the side surface 107S of the stringer 107, the user C can fasten the vertical leg 30 to the stringer via the second plurality of fasteners, which optionally can be the horizontal fasteners, in particular the fifth fastener 55, the sixth fastener 56 and the seventh fastener 57. This fastening also can be done via the tool 105. As shown in
[0061] A first alternative embodiment of the bracket is shown in
[0062] A second alternative embodiment of the bracket is shown in
[0063] Directional terms, such as vertical, horizontal, top, bottom, upper, lower, inner, inwardly, outer and outwardly, are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientations.
[0064] The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual elements of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles a, an, the or said, is not to be construed as limiting the element to the singular. Any reference to claim elements as at least one of X, Y and Z is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.