Modular staircase kit

Abstract

A staircase kit comprises a plurality of side panels and a plurality of inner and outer reinforcing panels disposed in layered arrangement over the side panels. The side panels and inner and outer reinforcing panels have preformed holes extending axially therethrough. The side panels are disposed in stacked relation to one another to form a plurality of module joints there between. Likewise, the inner reinforcing panels are disposable in overlapping relationship to the module joints. The inner reinforcing panels form a plurality of inner panel joints that are preferably disposed in staggered relationship to the module joints. The outer reinforcing panels are disposed in overlapping relationship to the inner panel joints to form a plurality of outer panel joints that are disposed in staggered relationship to the inner panel joints. The preformed holes of the side panels are axially alignable with the preformed holes of the inner and outer reinforcing panels such that mechanical fasteners may be installed at the job site in order to assemble the staircase kit for interconnection to a building structure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This is a continuation-in-part application of pending U.S. patent application Ser. No. 11 / 189,580 entitled MODULAR CURVILINEAR STAIRCASE and filed on Jul. 26, 2005, and is related to continuation-in-part U.S. patent application Ser. No. 11 / 273,206 also entitled MODULAR CURVILINEAR STAIRCASE filed on Nov. 14, 2005, the entire contents of both applications being expressly incorporated by reference herein.STATEMENT RE: FEDERALLY SPONSORED RESEARCH / DEVELOPMENT [0002] (Not Applicable) BACKGROUND OF THE INVENTION [0003] The present invention relates generally to building construction and, more particularly, to a uniquely configured modular staircase kit that is comprised of individual step modules that are pre-manufactured offsite using a specialized tooling fixture. The step modules are then assembled in stacked arrangement at a job site to form a staircase which may also be interconnected to a building structure such as a home. [0004] In bu...

AI Technical Summary

Benefits of technology

[0010] The present invention specifically addresses the above referenced needs associated with curved staircases. More specifically, the present invention is a uniquely configured staircase kit that may be prefabricated at an offsite location such as a factory. The staircase kit may be later assembled at a job site to form a staircase that may be attached to a building structure such as a house. The staircase kit may be configured to produce a straight staircase, a curved staircase, or any combination thereof. Advantageously, the staircase kit of the present invention may be accurately pre-manufactured offsite for later assembly at the job site using unskilled labor in order to reduce overall construction costs and assembly time.

[0017] The staircase kit may then be transported to a job site wherein the staircase kit may be reassembled in accordance with the positional markings. Mechanical fasteners such as nuts and bolts are then installed in the performed holes. Optionally, adhesive may be used in combination with the mechanical fasteners during re-assembly of the staircase kit to aid in securing the side panels with the inner and outer reinforcing panels. Adhesive such as suitable glue may enhance the load-carrying capabilities of the completed staircase.

Problems solved by technology

Unfortunately, prior art curved staircases are generally more expensive than straight staircases.

Such increased expense is due in large part to the cost of forming the curved portions of the curved staircase.

Furthermore, the installation of a curved staircase requires a higher degree of skill and is sometimes comparable to the high level of skill required in cabinet making.

The increased expense is also due in part to the time consuming manner in which such curved staircases are installed.

As may be appreciated, such conventional method for curved staircase construction is extremely time-consuming.

Furthermore, such conventional building method is highly dependent upon skilled labor and the availability of specialized tooling in order to produce a staircase that meets precise tolerance requirements mandated by local and national building codes.

Unfortunately, due to the difficulty in controlling the tolerances of the building structure to which the completed staircase is to be connected, problems with fitment of the curved staircase may occur.

In addition, generation of excess material wastage, schedule conflicts such as with framers, and issues in meeting building code requirements may develop.

Furthermore, the shipping of an entire completed curved staircase to a building structure many miles from the factory may entail significant logistical problems and may incur great expense.

In addition, the cost of pre-manufacturing such a curved staircase may run into the many thousands of dollars even prior to final installation into a building structure.

Finally, such prior art building construction of curved staircases may result in problems with the structural integrity of the curved staircase and, more particular, problems associated with the connection of the curved staircase to upper and lower levels of the building structure.

A common problem that may develop with curved staircases of the prior art is that staircase squeakage may occur over time due to gradual loosening of joints in the staircase.

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