Prefabricated stair components and stair tread finish systems and methods of making and using the same

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 (i) an upper support layer surface, (ii) a lower support layer surface, (iii) 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, and (iv) a lower support layer portion extending substantially perpendicular to the inner support layer edge surface and substantially parallel with and below 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 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.), and
• 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 front edge surface extends below the lower support layer surface.

A method of making a molded composite stair component, said method comprising:

• combining (i) a decorative finish layer comprising wood, textured or non-textured paper, a veneer layer, or any combination thereof, (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) an adhesive layer 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,
• wherein (1) the molded composite stair component comprises a lower support layer portion extending (i) substantially perpendicular to an inner support layer edge surface and (ii) substantially parallel with and below a lower support layer surface, (2) 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.), and (3) 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 front edge surface extends below the lower support layer surface.