# US 11,111,676 B2 · Prefabricated stair components and stair tread finish systems and methods of making and using the same

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- Number: US 11,111,676 B2
- Document ID: US11111676B2
- Status: Granted
- Kind: B2
- Application number: 16/554,673
- Filed: 2019-08-29
- Published: 2020-04-30
- Granted: 2021-09-07
- Earliest claimed: 2018-10-30
- Assignees: Summit Stairs of Atlanta, Inc.
- Applicants: Summit Stairs of Atlanta, Inc.
- Inventors: Glen A. Nedza
- Web page: https://patentgrep.com/patent/US11111676B2

## CPC

- E04F 11/166: {with means for fixing a separate edging strip}
- B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)}
- 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}
- 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}
- 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)}
- 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)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 7/06: permitting easy separation
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard}
- B32B 21/06: of paper or cardboard
- B32B 21/08: of synthetic resin
- B32B 21/10: Next to a fibrous or filamentary layer
- B32B 21/14: comprising wood board or veneer
- B32B 27/08: of synthetic resin
- B32B 27/10: of paper or cardboard
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/38: comprising epoxy resins
- B32B 27/40: comprising polyurethanes
- B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B32B 29/02: next to a fibrous or filamentary layer
- E04F 11/1045: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B32B 2250/04: 4 layers
- B32B 2250/05: 5 or more layers
- B32B 2255/08: on wood layer
- B32B 2255/12: on paper layer
- B32B 2255/26: Polymeric coating
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/026: Wood layer
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2262/105: Ceramic fibres
- B32B 2307/412: Transparent
- B32B 2307/414: Translucent
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B32B 2307/732: Dimensional properties
- B32B 2307/748: Releasability
- B32B 2307/75: Printability
- B32B 2419/00: Buildings or parts thereof
- B32B 2571/00: Protective equipment
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## 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

### Claim 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;
a composite profile such that the support layer comprises a molded support layer having (i) an upper support layer surface, (i) 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,
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.).

### Claim 2 (depends on 1)

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

### Claim 3 (depends on 2)

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

### Claim 4 (depends on 2)

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

### Claim 5 (depends on 2)

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

### Claim 6 (depends on 1)

The composite stair component of claim 1, 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 connected 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.

### Claim 7 (depends on 6)

The composite stair component of claim 6, wherein the upper support layer surface and the outer support layer front edge surface form a first curved surface profile.

### Claim 8 (depends on 7)

The composite stair component of claim 7, 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.

### Claim 9 (depends on 8)

The composite stair component of claim 8, 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.

### Claim 10

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.

### Claim 11 (depends on 10)

The composite stair component of claim 10, wherein the upper composite profile surface and the outer composite profile front edge surface form a third curved surface profile having a nose radius Rn, and the nose radius Rn is less than or equal to 0.5 in.

### Claim 12 (depends on 10)

The composite stair component of claim 10, 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.

### Claim 13 (depends on 12)

The composite stair component of claim 12, 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.

### Claim 14 (depends on 10)

The composite stair component of claim 10, 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.

### Claim 15 (depends on 10)

A stair comprising:
a stair tread comprising a stair nose;
a stair riser extending below said stair tread and said stair nose; and
the composite stair component of claim 10 at least partially covering one of more of: (i) said stair tread, (ii) said stair nose, and (iii) a bottom section of the stair nose.

### Claim 16

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.

### Claim 17 (depends on 1)

A stair comprising:
a stair tread comprising a stair nose;
a stair riser extending below said stair tread and said stair nose; and
the composite stair component of claim 1 at least partially covering one of more of: (i) said stair tread, (ii) said stair nose, and (iii) a bottom section of the stair nose.

### Claim 18 (depends on 1)

A method of making the composite stair component of claim 1, said method comprising:
combining (a) the decorative finish layer, and (b) the support layer; and
molding the decorative finish layer and the support layer to form the composite stair component.

### Claim 19 (depends on 3)

A stair comprising:
a stair tread comprising a stair nose;
a stair riser extending below said stair tread and said stair nose; and
the composite stair component of claim 3 at least partially covering one of more of: (i) said stair tread, (ii) said stair nose, and (iii) a bottom section of the stair nose.

### Claim 20 (depends on 4)

A stair comprising:
a stair tread comprising a stair nose;
a stair riser extending below said stair tread and said stair nose; and
the composite stair component of claim 4 at least partially covering one of more of: (i) said stair tread, (ii) said stair nose, and (iii) a bottom section of the stair nose.