Profile

Description

BE2024 / 5875 2 It is a goal of the invention to solve problems of pleated panels and stair coverings and of the state of the art. The first aspect of the invention is a stair shell, in which the stair shell contains a tread profile and a side cap. The tread profile contains a top side, a first panel section, and a curved transition section. The first panel section contains a support and a top layer. The curved transition section contains a top layer. The top layer of the first panel section continues continuously into the top layer of the curved transition section. The side cap is attached to one side of the tread profile. The side cap contains a support and a top layer. The side cap contains a first section and a second section, whereby the first section is thinner than the second section. Both the first section and the second section contain the top layer of the side cap. The first section is attached to one side of the first panel section, so that these sides are at least partially, and preferably completely, covered by the side cap.15 It is an advantage of the stair tread of the first aspect of the invention that a visually attractive stair tread is obtained that can be used for covering stairs. It is a further advantage that this stair tread can be produced from floor panels, so that the stair tread offers the same visual aspect as the floor panels on the stairs, or on the floor near the stairs. 20 In addition, the tread profile can be manufactured from a first floor panel; and the side cap can be manufactured from the same or from a second such floor panel. If these are panels that show a wood decor, a very beautiful imitation of a solid wood stair covering can be obtained. 25 It is a further advantage that the production of the stair tread according to the invention is simple. The side cap can be attached to the stair shell using glue.30 2024 / 5875 BE2024 / 5875 3 Preferably, a rear part of the thickness of the second section is located under the first panel part. This increases the strength and durability of the stair shell.The second section of the side cap preferably has a thickness equal to the thickness of the panel from which the side cap is made. This increases the strength and durability of the stair shell; and ensures simple production of the stair shell. The thickness of the second section is preferably more than 7 mm. A similar side cap can be provided on both sides of the stair shell, whether or not identical to each other. It is also possible that a similar side cap is provided on only one side of the stair shell. A stair shell containing a similar side cap on both sides can be used for covering a staircase that is open on both sides. A stair shell containing a side cap on only one side can, for example, be used for cladding a staircase that is open on one side and attached to a wall on the other.20 The top layer of the first panel section is preferably laminated onto the carrier of the first panel section. The top layer of the side cap is preferably laminated onto the carrier of the 25 side cap.In a preferred design, both the first and second sections of the lateral cap contain the support of the lateral cap, whereby the support in the first section of the lateral cap is thinner than in the second section of the lateral cap. Preferably, in terms of material, the support continues from the first section of the lateral cap into the second section of the lateral cap. 2024 / 5875 BE2024 / 5875 4 The first section of the lateral cap is indeed thinner than the second section of the lateral cap. Nevertheless, it is advantageous that the very first section of the lateral cap also contains the support of the lateral cap and not just the top layer of the lateral cap. This ensures sufficient strength of the lateral caps and of the stair shell as a whole. Preferably, the edge of the side cap follows the profile of the curved transition section. This results in a visually attractive stair shell that can be used as cladding for a staircase.10 It is possible to produce the side cap directly at its final dimensions and attach it to the stair shell, for example using glue.It is possible to produce the lateral cap slightly larger than necessary. More specifically, the first section of the lateral cap can be made slightly larger than necessary. After attaching the lateral cap to the stepped shell, protruding edges of the lateral cap can be cut away by means of mechanical processing (for example, by means of milling) so that a nicely fitting lateral cap is obtained in the stepped shell. In this way, tolerances can be accommodated and it is ensured that a visually attractive stepped shell is obtained. Preferably, the first section of the lateral cap covers the side of the curved transition section. This ensures a beautiful visual aspect of the stepped shell, which is also easy to produce. Preferably, the curved transition section contains a support, where the support of the curved transition section is formed by a continuous continuation of a part of the thickness of the support of the first panel section.2024 / 5875 BE2024 / 5875 5 Preferably, the curved transition section is thinner than the first panel section over at least part of its length. This design has the advantage that a visually more pleasing appearance can be achieved, since the curved transition section can be achieved through more precise folding. 5 The step profile may contain a second panel section, where the first panel section and the second panel section preferably have the same thickness. The first panel section and the second panel section are connected to each other via the curved transition section and form a single unit. 10 This design results in a step profile and a stair shell that are more robust. This second panel section may contain a top layer, which is the continuous continuation of the top layer of the first panel section via the top layer of the curved transition section. 15 Preferably, the second panel section contains a support made of the same material as the support of the first panel section.Preferably, the support of the second panel section is the continuous continuation of the support of the first panel section via the – preferably thinner – support of the curved transition section. 20 The lateral cap can contain a third section that is thinner than the second section. The third section contains the top layer, and preferably a support. The third section is attached to a side of the second panel section, so that these sides are at least partially, and preferably completely, covered. 25 This design offers a visually attractive stair shell that can be used for cladding a staircase, whereby the stair shell is also very robust. Preferably, a rear part of the thickness of the second section is located between the first panel section and the second panel section. This synergistically ensures a very robust30 stair shell. 2024 / 5875 BE2024 / 5875 6 Preferably, the first panel section, the curved transition section—and, if present, the second panel section—are manufactured from a single panel, at least by a bending operation to obtain the curved transition section.This results in a visually very attractive stair shell. 5 Preferably, the space between the first panel section and the curved transition section contains an insert. This design has the advantage that the tread profile and stair shell are easier to produce and more robust. The insert can be glued into the tread profile or mechanically attached, 10 for example by means of a click connection. In a preferred design of the stair shell, at least part of the curved transition section is bent over an insert. 15 Preferably, the side cap covers the side of the insert. Preferably, the first section of the side cap covers the side of the insert. This results in a visually very attractive stair shell. The top layer of the first panel section and the top layer of the curved transition section 20 may contain a decoration. The decoration may be a printed decoration; optionally combined with a texture, preferably a texture in register with the printed decoration.This decor can be a wood imitation, or an imitation of natural stone material, for example an imitation of marble. 25 The decor of the top layer of the first panel section preferably continues into the decor of the top layer of the curved transition section. The decor may also contain a layer of veneer, with or without one or more protective lacquer layers on it.30 2024 / 5875 BE2024 / 5875 7 A preferred design of the stair shell is characterized by the fact that the decor of the first panel and parts of the curved transition section on the one hand, and the decor of the lateral cap on the other hand, are the same decor. “The same decor” does not necessarily mean that both decors are identical, but that they offer a visual impression of the same decor. Both decors offer, for example, the same wood imitation or the same marble imitation, taking into account the inherent, natural variation of wood and marble. These designs ensure an even more visually attractive aspect of the stair shell. The stair shell then looks as if made of a natural material such as, for example, wood or marble.The carrier of the first panel section can be wood-based. The carrier of the first panel section can be or contain a wood fiber board – for example, an MDF (Medium Density Fiberboard) or an HDF (High Density Fiberboard) board. The carrier of the first panel section can be or contain a particle board. The carrier of the first panel section can contain a layer containing wood chips. A counter layer can be applied to or laminated onto the carrier of the first panel section, for example, a paper impregnated with thermosetting resin. This counter layer can serve as a balance layer to relieve stresses in the panel caused by the application of the top layer. The carrier of the first panel section can be a thermoplastic board, whether filled or not, for example, a polyvinyl chloride-based board, a polyester-based board, a polypropylene-based board, or a polyethylene-based board. Fillers can be organic fillers (for example, wood fibers or wood dust) or mineral fillers (for example, calcium carbonate). The support of the lateral cap can be wood-based.The carrier of the side cap can be or contain a wood fiber board – for example, an MDF (Medium Density Fiberboard) or an HDF (High Density Fiberboard) board. The carrier of the side cap can be or contain a chipboard. The carrier of the side cap can contain a layer that contains wood chips. A counter layer can be applied or laminated to the carrier of the side cap, for example, a paper impregnated with thermosetting resin. This counter layer can have the function of a balancing layer. This counter layer can have the function of a balancing layer to relieve stresses in the panel caused by the application of the top layer. The carrier of the lateral cap can be a filled or unfilled thermoplastic sheet, for example a polyvinyl chloride-based sheet, a polyester-based sheet, a polypropylene-based sheet or a polyethylene-based sheet. Fillers can be organic fillers (for example wood fibres or wood dust) or mineral fillers (for example calcium carbonate).The decoration of the top layer of the first panel section can be a wood decoration; and the decoration of the side cap can be a wood decoration; where the grain of the wood decoration of the top layer of the first panel section runs parallel to the curved transition section; and where the grain of the wood decoration of the side cap in the stepped shell forms an angle of 90° with the first panel section. 20 This design provides a visually very attractive stepped shell, because it gives the impression that the stepped shell is made of solid wood. The decoration of the top layer of the first panel section can be a wood decoration; and the decoration of the side cap can be a wood decoration; where the grain of the wood decoration of the top layer of the first panel section in the stepped shell runs parallel to the grain of the wood decoration of the side cap. This design creates a visually very attractive stairwell shell, because it gives the impression that the shell is made of solid wood.30 2024 / 5875 BE2024 / 5875 9 The decor of the top layer of the first panel section can be a wood decor; and the decor of the side cap can be a wood decor, whereby the grain of the wood decor of the top layer of the first panel section runs parallel to the curved transition section; and whereby the grain of the wood decor of the side cap in the stair shell forms an angle of 90° with the direction of the grain of the wood decor of the top layer of the 5 first panel section. This design form is easy to produce from identical floor panels. Preferably, the support of the first panel section and the support of the side cap are made of the same material. 10 Preferably, the first panel section and the second section of the side cap have the same thickness. The first panel section and the curved transition section can be made from a first decorative panel containing a support and a top layer. The lateral cap can be made from the same panel, or from another similar panel. These designs have the advantage that fewer types of raw materials are needed to produce the stair shell.The first panel section, the curved transition section, and the side cap can therefore have the same top layer; this means that they have the same decoration. However, it is also possible that the side cap is made from a panel with a different decoration, or even from a different type of decoration, than the first panel section, the curved transition section, and, if present, the second panel section. The top layer of the first panel section can consist of a printed sheet of paper (preferably meth-impregnated) or a printed polymer film. Optionally, the top layer of the first panel section can contain a wear layer, for example a meth-impregnated sheet of paper, or one or more coating layers, for example one or more acrylate coating layers. 2024 / 5875 BE2024 / 5875 10 The top layer of the first panel section may contain a layer of veneer, with an optional wear layer, for example one or more lacquer layers, for example acrylate lacquer layers. The top layer of the first panel section may contain printing on the substrate, and5 optionally a wear layer.The top layer of the side cap can contain a printed sheet of paper (preferably meth-impregnated) or a printed polymer film. Optionally, the top layer of the side cap can contain a wear layer, for example a meth-impregnated sheet of paper or one or more coating layers, for example one or more acrylate coating layers. The top layer of the side cap can contain a veneer layer, with an optional wear layer, for example one or more lacquer layers, for example acrylate lacquer layers. The top layer of the side cap can contain a print on the carrier of the side cap, and optionally a wear layer. Preferably, the first section of the side cap has a thickness of less than 2 mm, with a higher preference a thickness of less than 1.5 mm, and with a higher preference a thickness of less than 1 mm. The thickness of the first section of the side cap can be, for example, 0.8 mm. Such designs have the advantage that the transition between the lateral caps and the first panel section is barely visible. This enhances the visually attractive aspect of the stair shell when used as cladding for a staircase.The side cap can have a rectangular shape, with at least one rounded corner on the curved transition section. Other corners of the rectangular shape can also be rounded. 2024 / 5875 BE2024 / 5875 11 In a preferred design, the space between the first panel section and the curved transition section contains an insert; and the space between the first panel section and the curved transition section contains a second insert. Such designs allow the stair shell to be given a specific, desired shape; a shape that allows for a visually attractive stair shell to be achieved. Preferably, at least part of the curved transition section is bent over the insert. Preferably, the insert in the stair shell is glued or mechanically fastened. This mechanical fastening can be done, for example, by means of a snap connection. 15 Preferably, at least part of the curved transition section is bent over the second insert. Preferably, the second insert is glued or mechanically fastened in the step profile.This mechanical fastening can be done, for example, by means of a click connection20. The curved transition section can contain a first curved zone at the insert and a second curved zone at the second insert. Optionally, the curved transition section can contain a straight25 zone between the first curved zone and the second curved zone. The curved transition section can be thicker in the straight zone than in both the first curved zone and the second curved zone. Preferably, the curved transition section in the straight zone has the same thickness as the first panel section.30 2024 / 5875 BE2024 / 5875 12 These design forms ensure an easy-to-produce step profile that is very sturdy when used as stair covering. The first panel section can contain a male or female coupling part on the side opposite the curved transition section, configured for coupling to a female or male coupling part of a floor panel, respectively.The coupling part of the first panel section on the side opposite the curved transition section is preferably configured for a connection where interlocking occurs perpendicular to the top of the first panel section; and / or where interlocking occurs in the plane of the top of the first panel section and perpendicular to the coupled edges. In a preferred configuration, the first panel section on the side opposite the curved transition section contains a female coupling part. This female coupling part includes a groove. This female coupling part is configured for connecting the first panel section to the edge of a floor panel. Preferably, the female coupling part is configured for a connection where interlocking occurs perpendicular to the top of the first panel section; and / or where interlocking occurs in the plane of the top of the first panel section and perpendicular to the coupled edges.These design forms allow the use of the tread profile of the invention in a stair covering, whereby the profile contains the stair nose and a floor panel can be easily coupled on the stair tread to the groove of the first panel section of the tread profile. Naturally, it is possible—and preferred—for the floor panel to be coupled on the one hand and the first panel section on the other hand to have the same decoration. In a preferred design, the tread profile contains a floor panel. The first panel section contains a coupling part on the side opposite the curved transition section. The first panel section with the coupling part coupled to a corresponding coupling part 2024 / 5875 BE2024 / 5875 13 of the floor panel, whereby the first panel section and the floor panel are coupled in one plane. The first section of the lateral cap covers at least one lateral edge of the floor panel. Such a stair shell leads to a visually attractive stair covering that is easy to produce and can be easily installed on a staircase.Preferably, a rear part of the thickness of the second section is located under the floor panel. 10 Preferably, when coupling the coupling part of the first panel to the coupling part of the floor panel, a locking mechanism occurs perpendicular to the top side of the first panel and / or a locking mechanism occurs in the plane of the top side of the first panel and perpendicular to the coupled edge of the first panel. 15 The coupling part of the first panel on the side opposite the curved transition section preferably contains a groove between an upper lip and a lower lip. The corresponding coupling part of the floor panel preferably contains a tooth, whereby in the coupled state, the tooth in the groove provides a locking mechanism in the direction perpendicular to the top side of the first panel.20 With higher preference the lower lip contains an upward-pointing projection and the tooth contains a corresponding recess, whereby in the coupled state the projection and the corresponding recess provide a locking mechanism in the plane of the top side of the first panel part and perpendicular to the coupled lip of the first 25 panel part. An aspect of the invention is a set for covering a stair tread with a stair shell as in any execution form of the first aspect of the invention. The set contains a tread profile and a side cap. The tread profile and the side cap can each be configured as described in execution forms of the stair shell of the first aspect of the invention. 2024 / 5875 BE2024 / 5875 14 An aspect of the invention is a set for covering a stair tread with a stair shell as in any form of execution of the first aspect of the invention. The set contains a tread profile and a side cap.The lateral cap contains an assembled state with a horizontally oriented plane of symmetry, or possesses an assembled state with a vertically oriented plane of symmetry, or both. An excess of the lateral cap can be sawn off for use in the stair shell. The tread profile and the lateral cap can each be configured as described in execution forms of the stair shell of the first aspect of the invention. An aspect of the invention is a staircase, characterized by the fact that the staircase contains at least one tread covered with a stair shell as in any execution form of the first aspect of the invention.With the aim of better demonstrating the characteristics of the invention, several preferred forms of execution are described below as examples without any restrictive character, with reference to the accompanying drawings, in which: figures 1 and 2 illustrate a stair shell according to the invention for a stair covering; figure 3 shows a detail of the stair shell; figures 4 and 5 show details of the tread profile; figures 6–10 show details of the side cap; figure 11 shows a detail of the connection between the first panel section and a floor panel; figure 12 shows a staircase covered with stair shells according to the invention; and figures 13 and 14 show alternatives for a side cap for a stair shell according to the invention. The reference numbers have the same meaning in the different figures.30 2024 / 5875 BE2024 / 5875 15 Figures 1 and 2 show an example of a stair shell10 according to the invention for the covering of a staircase. The stair shell10 contains a tread profile12 and a side cap 25.Figure 1 shows the stair shell 10 under construction, with the tread profile 12 and where the 5 side cap 25 still needs to be attached. Figure 2 shows the stair shell 12 in which the side cap 25 is mounted. The tread profile 12 for covering a stair tread contains a floor panel 73 in the example. 10 The tread profile 12 has a top side 14. The tread profile 12 contains a first panel section 16, a curved transition section 17, and a second panel section 40. The side cap 25 is attached to the side of the tread profile 12. The edge of the side cap 25 follows the stair shell of the curved transition section 17. 15 Figures 4 and 5 show details of the tread profile 12. The first panel section 16 contains a carrier 19 and a top layer 20. The top layer 20 is laminated onto the carrier 19 in the example. 20 The curved transition section17 contains a top layer22 and a support37. The top layer20 of the first panel part16 continues into the top layer22 of the curved transition section17. The first panel part16 and the second panel part40 are connected to each other via the curved25 transition section17 and form a single unit.The second panel part 40 contains a top layer 39, which is the continuous continuation of the top layer 20 of the first panel part 16 via the top layer 22 of the curved transition section 17.30 2024 / 5875 BE2024 / 5875 16 The top layer 20 of the first panel part 16, the top layer 22 of the curved transition section 17 and the top layer of the second panel part 39 – top layers that flow into each other – contain a continuous printed decor, optionally with texture. This decor can imitate a wood structure. 5 The second panel part 40 contains a support 23 made of the same material as the support 19 of the first panel part 16 and the support 37 of the transition section. The support 19 of the first panel part 16 continues, albeit thinner than the support 37 of the transition section 17, into the thicker support 23 of the second panel part 40.10 The second panel part 40 has the same thickness as the first panel part 16. The top layers 20, 22, 23 of the first panel part 16, the transition section 17 and the second panel part respectively have the same thickness and are the continuous extensions of 15 each other. Figures 6–10 show details of the lateral cap 26.The side cap25 is shown in figure 6, cross-section in figures 7 and 8, and details thereof in figures 9 and 10. 20 The side cap25 contains a support 27 and a top layer 28. In the example, the top layer 28 is laminated onto the support 27. The top layer 28 of the side cap25 contains a printed decor, optionally with texture. This decor can imitate a wood decor. 25 The side cap25 contains a first section31, a second section32 and a third section 44. The first section31 and the third section44 are thinner than the second section32. In the example, the second section32 has the same thickness as the first panel part16. In the example, the first section31 has the same thickness as the third section44, for example 0.8mm.30 2024 / 5875 BE2024 / 5875 17 Both the first section31, the second section32 and the third section44 contain the top layer 28 of the side cap25. The first section31 of the lateral cap25 is attached to a side33 of the first panel section16, so that this side is covered by the lateral cap25. The first section31 also covers the side of the curved transition section17.A rear part35 of the thickness of the second section31 is located under the first panel part16; and more specifically between the first panel part16 and the second panel part 40. This is clarified in Figure 3.10. Figure 3 shows a detail of the stair shell10. Figure 3 also shows that the first section31 of the lateral cap25 may have been made slightly larger than necessary. After attaching the lateral cap25, this excess38—shown in the dotted line in Figure 3—can be removed by mechanical operation, so that the contour of the first section31 fits nicely. Both the first section31, the second section32, and the third section44 of the lateral cap25 containing the support27. The support27 is thicker in the second section32 than in the first section31 and than in the third section44. The material of the support27 of the lateral cap25 runs from the first section31 into the second section32, and from the second section32 into the third section44. The curved transition section17 is thinner along part of its length than the first panel section16.25 The space between the first panel section16 and the curved transition section17 contains an insert50.Part of the curved transition section 17 is bent over the insert. The insert 50 is glued with adhesive 52 into the stair shell 12. Alternatively, the insert can be mechanically fastened. 30 2024 / 5875 BE2024 / 5875 18 The space between the first panel part 16 and the curved transition section 17 contains a second insert 60. Part of the curved transition section 17 is bent over the second insert 60. The second insert 60 is glued into the stair shell 12. Alternatively, the second insert 60 can be mechanically fastened. 5 In the example shown, the curved transition section 17 contains a first curved zone 61 at the insert 50, a second curved zone 62 at the second insert 60; and between the first curved zone 61 and the second curved zone 62 a straight zone 63. The straight zone 63 is thicker than the first curved zone 61 and than the second curved zone 62. In the example, the straight zone has the same thickness as the first 10 panel part 16 and as the second panel part 40. The side cap 25 covers – by means of the first section 31 of the side cap 25 – the side of the insert 50 and the side of the second insert 60.15 The first panel section16, the curved transition section17 and the second panel section40 can be made from a single panel. This panel contains a carrier and a top layer. The carrier can be a wood-based carrier, for example a wood fibreboard. The top layer can be a decoratively printed sheet of paper, with or without a wear layer. The top layer is laminated onto the carrier. This panel can be a laminate panel, for example20 produced according to the DPL (Direct Pressure Laminate) method. Other types of panels can also be used. By milling away the back of this panel and bending—for example, at an elevated temperature—the curved transition section 17 can be formed. The first panel part 16 and the second panel part 40 are straight sections of the panel used. In this way, the top layer 20 of the first panel part 16 continues via the top layer 22 of the curved transition section 17 into the top layer 23 of the second panel part 40. 30 The lateral cap 25 can be manufactured from the same panel or from a second similar panel.In this way, the capping 25 has the same decorative 2024 / 5875 BE2024 / 5875 19 aspect – for example, the same wood decor – as the combination of the first panel section 16, the curved transition section 17 and the second panel section 40. However, it is also possible that the capping 25 is made from a panel with a different decor, or even from a different type of decor. 5 When produced from panels that imitate a wooden plank, the capping can be produced and assembled in such a way that the grain of the wood decor of the top layer of the first panel section runs parallel to the curved transition section; and that the grain of the wood decor of the capping in the stair shell forms a 90° angle with the first panel section. This offers an imitation of a stair shell for the cladding of a solid wood staircase. When produced from panels that imitate a wooden plank, the lateral cap can be produced and mounted in such a way that the grain of the wood decor of the top layer of the first panel section runs parallel to the grain of the wood decor of the lateral cap in the stair shell.This offers an imitation of a stair tread for the cladding of a solid wood staircase. When produced from panels that imitate a wooden plank, the side cap can be produced and mounted in such a way that the grain of the wood decor of the top layer of the first panel section runs parallel to the curved transition section; and that the grain of the wood decor of the side cap in the stair tread forms an angle of 90° with the direction of the grain of the wood decor of the top layer of the first panel section. The stair tread for the stair cladding in the example contains a floor panel. The first section of the side cap covers a side edge of the floor panel, whereby a rear part of the thickness of the second section is located under the floor panel. 30 As illustrated in Figure 11, the first panel part 16 contains a coupling part on the side opposite the curved transition section 17. This coupling part 2024 / 5875 BE2024 / 5875 20 contains a groove 70 between an upper lip 75 and a lower lip 76. The floor panel 73 contains a corresponding coupling part.This corresponding coupling part of the floor panel73 contains a tooth71. In the coupled state, the tooth71 and the groove70 provide a locking mechanism in the direction perpendicular to the top side14 of the first panel part16. The lower lip76 contains an upward-facing projection78 and the tooth5 71 contains a corresponding recess79. In the coupled state, the projection and the corresponding recess provide a locking mechanism in the plane of the top side14 of the first panel part16 and perpendicular to the coupled edge of the first panel part16. 10 Figure 12 shows a staircase80 whose treads82 are covered with stair shells12 as shown in Figure 2. The other reference numbers in Figure 12 have the same meaning as in the other figures. Figure 13 shows an alternative lateral cap25 for a stepped shell according to the 15 invention. Figure 13 shows this lateral cap25 in the same view as Figure 6. The reference numbers in Figure 13 have the same meaning as in the other figures. The lateral cap25 of Figure 13 is symmetrical.Depending on whether one or the other side of a step profile 12 needs to be covered by the side cap 25, one of the sides of the side cap 25 can be sawn, for example, for use when the side cap 25 in the stair shell 10 of figures 1 and 2 is sawn at line 50, so that the side cap of figure 6 is obtained. Figure 14 shows an alternative side cap 25 for a stair shell according to the invention. This side cap 25 can be supplied in a set together with a step profile, for installation on a stair step of a stair shell according to the invention. The side cap 25 of figure 14 contains two planes of symmetry 52, 54, which allow the side cap 25 to be used rotated in different ways. To this end, an unnecessary part of the lateral cap can be sawn off in the same way as shown in Figure 13.