PREFABRICATED STAIR COMPONENTS AND STAIR TREAD FINISH SYSTEMS AND METHODS OF MAKING AND USING THE SAME

• US 20200131779A1
• Filed: 08/29/2019
• Published: 04/30/2020
• Est. Priority Date: 10/30/2018
• Status: Active Grant

• Current Assignee: SSM Holdco LLC
• Original Assignee: Summit Stairs Of Atlanta, Inc.
• Inventors: Nedza, Glen A
• Granted Patent: US 11,111,676 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/06 of paper or cardboard
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2250/04 4 layers
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/12 on paper layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/026 Wood layer
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/105 Ceramic fibres
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/414 Translucent
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2307/748 : Releasability
• CPC Class Codes: B32B 2307/75 : Printability
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2571/00 : Protective equipment
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/10 : of paper or cardboard
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 27/42 : comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 29/005 : next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 29/02 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 3/02 : characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 3/04 : characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/028 : Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 7/06 : permitting easy separation
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• 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 11/166 : with means for fixing a separate edging strip

Abstract

Prefabricated stair components and stair tread finish systems are disclosed. Methods of making and using prefabricated stair components and stair tread finish systems are also disclosed.

Claims

1. A composite stair component comprising:

a decorative finish layer comprising wood, textured or non-textured paper, a veneer layer, or any combination thereof;

a support layer comprising wood, medium density fiberboard (MDF), polyvinyl chloride (PVC), a polymeric material, a composite material, or any combination thereof; and

at least one of;

a hinge layer positioned between said decorative finish layer and said support layer, said hinge layer comprising a film layer, a fiber-containing layer, a fabric layer, or any combination thereof, and

a composite profile such that the support layer comprises a molded support layer having an upper support layer surface, a lower support layer surface, and an inner support layer edge surface, at least a portion of the inner support layer edge surface being substantially perpendicular to the lower support layer surface.

2. The composite stair component of claim 1, wherein the support layer comprises a molded support layer, and the molded support layer comprises polyvinyl chloride (PVC).

3. The composite stair component of claim 2, wherein the decorative finish layer comprises wood.

4. The composite stair component of claim 2, wherein the decorative finish layer comprises a veneer layer.

5. The composite stair component of claim 2, wherein the decorative finish layer further comprises a resin that coats, impregnates and/or encompasses the wood, the textured or non-textured paper, and/or the veneer layer.

6. The composite stair component of claim 2, wherein the hinge layer is present and comprises a film layer.

7. The composite stair component of claim 1, wherein the composite stair component comprises the composite profile.

8. The composite stair component of claim 7, wherein the molded support layer further comprises a lower support layer portion extending (i) substantially perpendicular to the inner support layer edge surface and (ii) substantially parallel with and below the lower support layer surface.

9. The composite stair component of claim 8, wherein the lower support layer portion comprises an upper inner support layer surface below the lower support layer surface, and the upper inner support layer surface is a distance d from an upper composite profile surface, and distance d is less than or equal to 1.0 inch (in.).

10. The composite stair component of claim 7, wherein the molded support layer further comprises an outer support layer front edge surface, wherein (i) the outer support layer front edge surface extends from and is connect to the upper support layer surface, and (ii) at least a portion of the outer support layer edge surface extends below the lower support layer surface.

11. The composite stair component of claim 10, wherein the upper support layer surface and the outer support layer front edge surface form a first curved surface profile.

12. The composite stair component of claim 11, wherein the molded support layer further comprises an outer lowermost support layer edge surface, wherein (i) the outer lowermost support layer edge surface extends from and is connected to the outer support layer front edge surface, and (ii) at least a portion of the outer lowermost support layer edge surface extends below the upper inner support layer surface.

13. The composite stair component of claim 12, wherein the upper support layer surface and the outer support layer front edge surface and the outer lowermost support layer edge surface form a second curved surface profile.

14. A composite stair component comprising:

a decorative finish layer comprising wood, textured or non-textured paper, a veneer layer, or any combination thereof;

a molded support layer having an upper support layer surface, a lower support layer surface, and an inner support layer edge surface, at least a portion of the inner support layer edge surface being substantially perpendicular to the lower support layer surface, said molded support layer comprising wood, medium density fiberboard (MDF), polyvinyl chloride (PVC), a polymeric material, a composite material, or any combination thereof; and

an adhesive layer positioned between the decorative finish layer and the molded support layer,

wherein the composite stair component comprises an upper composite profile surface and an outer composite profile front edge surface, and (i) the outer composite profile front edge surface extends from and is connected to the upper composite profile surface, and (ii) at least a portion of the outer composite profile edge surface extends below the lower support layer surface.

15. The composite stair component of claim 14, wherein the upper composite profile surface and the outer composite profile front edge surface form a third curved surface profile having a nose radius R_n, and the nose radius R_n is less than or equal to 0.5 in.

16. The composite stair component of claim 14, wherein the composite stair component further comprises an outer lowermost composite profile edge surface, wherein (i) the outer lowermost composite profile edge surface extends from and is connected to the outer composite profile front edge surface, and (ii) at least a portion of the outer lowermost composite profile edge surface extends below the upper inner support layer surface.

17. The composite stair component of claim 16, wherein the decorative finish layer extends along the upper composite profile surface, the outer composite profile front edge surface, and the outer lowermost composite profile edge surface.

18. The composite stair component of claim 14, further comprising:

a protective surface wear layer over said decorative finish layer, said protective surface wear layer comprising at least one resin or polymeric material.

19. A stair comprising:

a stair tread comprising stair nose;

a stair riser extending below said tread and stair nose; and

the composite stair component of claim 14 at least partially covering one of more of;

(i) said tread, (ii) said stair nose, and (iii) said bottom section of the nose.

20. A method of making the composite stair component of claim 14, said method comprising:

combining (i) the decorative finish layer, (ii) a support layer comprising wood, medium density fiberboard (MDF), polyvinyl chloride (PVC), a polymeric material, a composite material, or any combination thereof, and (ii) the adhesive layer with one another so that the adhesive layer is positioned between the decorative finish layer and the support layer; and

molding the decorative finish layer, the adhesive layer and the support layer.