STAIR TREAD ASSEMBLY AND METHOD

• US 20110179729A1
• Filed: 10/07/2009
• Published: 07/28/2011
• Est. Priority Date: 10/07/2009
• Status: Active Grant

• Current Assignee: Moulure Alexandria Moulding Incorporated (U.S. Lumber Group LLC)
• Original Assignee: Moulure Alexandria Moulding Incorporated (U.S. Lumber Group LLC)
• Inventors: THOMPSON, Marianne
• Granted Patent: US 8,316,594 B2
• Time in Patent Office: Days
• US Class Current: 52/179
• CPC Class Codes: E04F 11/104 Treads
• CPC Class Codes: E04F 11/1045 composed of several layers, e.g. sandwich panels layered products in general B32B; producing decorative panels or veneers B44C5/04
• CPC Class Codes: E04F 11/175 Covering panels for tread restoration

Abstract

A replacement or repair stair tread assembly for covering over an existing worn stair tread includes a core that is surrounded by hardwood edge members, of which at least on edge has a bullnose. The edge members and core are mated at tongue and groove joints. The bullnose has a greater depth of section than the core. The core is a multi-ply matrix with veneer surface skins of the same grain orientation and type of wood. The multiple plies are arranged such that successive layers have cross-wise grain orientation. The plies of the core have symmetrically balanced properties relative to the neutral axis or neutral plane of the core in bending, both cross-wise and length-wise. The balanced properties may pertain to water absorption and to resistance to bending.

Claims

1. A replacement stair tread assembly comprising:

a core member, said core member having a thickness, a step wise depth, and a cross-wise width, said step-wise depth and said cross-wise width being greater than said thickness;

said core member having a wood-based core matrix, said core matrix having a plurality of overlying layers, said matrix having substantially uniform properties of mechanical elasticity cross-wise, and having substantially uniform properties of mechanical elasticity stepwise;

said matrix having an upper surface and an opposed lower surface;

said core including at least a first wood veneer portion mounted to said upper surface of said core matrix, and a second wood veneer portion mounted to said lower surface of said core matrix, said first and second wood veneer portions lying in parallel planes;

said core member having a quadrilateral form when viewed looking in a direction perpendicular to said plane of said first wood veneer portion;

said core member having a periphery and an array of edge members mounted about said periphery such that said core matrix is concealed from view;

said edge members being made of solid hardwood;

said edge members including at least a first nosed edge member;

said edge members including at least a first un-nosed edge member;

said core having a first edge portion for mating engagement with said first un-nosed edge member, said first edge portion having a first profile machined along at least a first portion thereof;

said first un-nosed edge member having a second profile machined therealong;

said first and second profiles including out-of-plane features;

said first and second profiles being mutually mating profiles;

said first un-nosed edge member having a through thickness matching said core such that when said first and second profiles are mated said first un-nosed edge member mates flush with said first wood veneer portion of said core;

said core having a second edge portion for mating engagement with said first nosed edge member, said second edge portion having a third profile;

said first nosed edge member having a fourth profile machined therealong;

said third and fourth profiles being mutually mating profiles such that when mated together said first nosing is flush with said first wood veneer portion of said core; and

said nosing having an overall height greater than said thickness of said core.

2. The replacement stair tread assembly of claim 1 wherein said first nosed edge portion is oriented cross-wise to said first un-nosed edge portion, said first un-nosed edge portion has a first end;

and said third profile is cut across said first end of said first un-nosed portion, said first nosed edge portion having an end region mated to said first end of said first un-nosed edge portion.

3. The replacement stair tread assembly of claim 1 wherein said first nosing edge member includes a bullnose, and said bullnose has a through thickness greater than said thickness of said core.

4. The replacement stair tread assembly of claim 3 wherein said first nosing edge member includes a depending edge located stepwise inwardly of said bullnose, said depending edge having a rearward facing abutment surface for engaging an existing stair.

5. The replacement stair tread assembly of claim 1 wherein said stair tread includes four edge members in a set, the set including any one of:

(a) first, second and third nosed edge members and said first un-nosed edge member;

(b) first and second nosed edge members and first and second un-nosed edge members; and

(c) said first nosed edge member and first, second and third un-nosed edge members.

6. The replacement stair tread assembly of claim 1 wherein said core matrix is a plywood matrix.

7. The replacement stair tread assembly of claim 1 wherein said hardwood is chosen one of (a) red oak;

(b) white oak;

(c) maple;

(d) walnut; and

(e) cherry.

8. The replacement stair tread assembly of claim 1 wherein said core has a through thickness of less than ¾

inches.

9. The replacement stair tread assembly of claim 8 wherein said first nosed edge member includes a bullnose, and said bullnose has a through thickness of at least 1 inch.

10. The replacement stair tread assembly of claim 9 wherein said core is substantially rectangular and has a pair of long edges and a pair of short edges;

said first un-nosed edge extends along one of said long edges; and

, when assembled, said core and said first un-nosed edge, taken together, have an overall dimension step-wise of at least 7½

″

.

11. The replacement stair tread assembly of claim 10 wherein said bullnose has a depending flange, and said depending flange has a rearwardly facing abutment surface for engagement of an existing stair, said rearwardly facing abutment surface extending in a plane flush with a forward edge of said first wood veneer portion.

12. The replacement stair tread assembly of claim 1 wherein said first profile is a tongue and said second profile is a mating groove.

13. The replacement stair tread assembly of claim 1 wherein said third profile is a tongue and said fourth profile is a mating groove.

14. The replacement stair tread of claim 1 where said first and third profile are the same, and said second and fourth profiles are the same.

15. A replacement stair tread assembly for covering over an exiting stair tread, said replacement stair tread assembly comprising:

a core having a periphery including a stepwise leading edge, a stepwise trailing edge, and first and second cross-wise end edges;

said core having matched hardwood upper and lower surface layers;

edge members extending fully about said periphery of said core;

said edge members including at least a first nosed edge member mounted along said stepwise leading edge;

said core and edge members having interlocking profiles that are mated together;

said core having a neutral axis;

said core having multiple layers with cross-wise variation of grain direction between successive layers; and

said core having a cross-section that is matched above and below said neutral axis.

16. The replacement stair tread of claim 15 wherein said core has a cross-wise length and a stepwise tread distance, and a ratio of said length to tread distance is in the range of greater than 36:

9½

.

17. A replacement stair tread assembly for covering over an exiting stair tread, said replacement stair tread assembly comprising:

a full width core having a periphery including a stepwise leading edge, a stepwise trailing edge, and first and second cross-wise end edges;

said full width core having a cross-wise length of at least 30 inches;

edge members extending fully about said periphery of said core;

said edge members including at least a first nosed edge member mounted along said stepwise leading edge;

said core and edge members having interlocking profiles that are mated together;

said core having a neutral axis;

said core having multiple full width layers with cross-wise variation of grain direction between successive layers; and

said core having a cross-section that has substantially matched physical properties above and below said neutral axis.

18. The replacement stair tread assembly of claim 17 wherein said substantially matched physical properties include moisture absorption.

19. The replacement stair tread assembly of claim 17 wherein said substantially matched physical properties include resistance to out of plane bending in both cross-wise and step-wise orientation.