US 5,163,491 A · Methods of manufacturing curved staircases and staircases produced

Abstract

Improved methods of fabricating at least partially curved staircases include a first method in which preformed step structures have treads with curved slots formed in the underside of the ends which define a path for insertion of top edge segments of thin starter strips. The slots are collectively configured to laterally deflect the inserted starter strips in a manner longitudinally conforming them to at least partially curved paths of the overall stringer structures in the completed staircase. The stringers are then laterally built up and completed by securing reinforcing structures to the side surfaces of the laterally deflected strips. A second method uses preformed cooperating treads and risers themselves as a form which defines an at least partially curved path for the stringers. Simple temporary supports both position the cooperating treads and risers and provide a solid support for laying up strips from the inside out to form stringers to support the stair and back finishing strips along curved paths defined by the cooperating treads and risers wherein the finishing strips have edges configured to interengage the outer ends of the cooperating treads in a rigid assembly and form smooth sides of the staircase. The procedure is designed to allow the stringers to be made from flexible strips which are conveniently boxable and shippable because smooth butt joints are made while the ends are solidly supported and thus prefabricated staircase kits are made practical.

Claims24

Dependent claims

The method of fabricating an at least partially curved staircase having a series of step structures which span and are secured to a lateral duality of elongated stringer structures longitudinally extending along at least partially curved paths at opposite sides of the staircase, said method comprising the steps of:

forming first and second relatively thin, hand-bendable lateral portions of said stringer structures, said hand-bendable portions being strips having an upper edge portion having longitudinal segment means adapted for receiving curved end portions of steps along said at least partially curved paths;
forming said step structures having end portions in which are formed curved surface slot means for receiving said longitudinal segments of said hand-bendable stringer strips structures in corresponding lengths therewith when received;
operatively securing longitudinal segment portions of the hand-bendable stringer strips into said curved surface slot means to transversely deflect said hand-bendable lateral portions of said stringer structures to longitudinal conformance with said at least partially curved paths;
and
securing reinforcing structures to the deflected lateral portions of the hand-bendable portions of said stringer strips after said step structures are operatively secured thereto, defining the balances of said stringer structures.

2 more elements

The method of fabricating an at least partially curved staircase which employs the treads and risers as a form for defining an at least partially curved path to be followed by inside and outside stringers laid up along curved paths from flexible stringer strips, the method comprising:

forming cooperating treads and risers for a curved run of staircase, the treads having opposite end portions, having an inside end portion formed to define an inside curved path and an opposite outside end portion formed to define an outside curved path;
positioning some of said cooperating treads and risers into a desired curved operating position along a portion of said curved run;
supporting said some cooperating treads and risers in said curved operating position by means of inside and outside supports located laterally inwardly from the opposite inside and outside end portions of the treads at a lateral position wherein a side of each support defines the location of the innermost side edge of respective inside and outside stringers which when completed will have an opposite side edge lying along one of said at least partially curved paths;
connecting the rest of said cooperating treads and risers for the rest of said curved run to the said some cooperating treads and risers and positioning and supporting them along the remainder of the said curved run by addtional ones of said supports having side edges located to define said innermost side edges of said respective inside and outside stringers at a plurality of places along said run, said inside and outside stringers when completed each having an opposite side edge lying along one of said at least partially curved paths;
and
forming said respective inside and outside stringers by laying up multiple flexible strips along said supports in supporting contact with said cooperating treads and risers until the last of said strips of the respective inside and outside stringers so formed lie along said at least partially curved paths defined by the opposite end portions of said cooperating treads and risers.

3 more elements

Dependencies are inferred from the claim text.

Methods of manufacturing curved staircases and staircases produced

Life of this patent

Methods of manufacturing curved staircases and staircases produced

Life of this patent

Abstract

Claims24