Book matched stair tread and method of manufacture

Abstract

A stair tread includes a rectangular base core including a plurality of elongated wooden base strips, and a rectangular upper plate disposed above the rectangular base core, the rectangular upper plate including a plurality of elongated solid wood upper plate strips of formed from the same solid wood. The rectangular upper plate is non-moveably secured to the rectangular base core so as to be disposed above the rectangular base core. The plurality of elongated wooden base strips are geometrically identical and have uniform thickness, width and length. Similarly, the plurality of elongated solid wood upper plate strips are geometrically identical and book-matched, and have uniform thickness, width and length.

Description

CROSS-REFERENCE TO RELATED APPLICATION AND CLAIM TO PRIORITY

[0001] This Application claims the benefit of U.S. Provisional Patent Applications Ser. No. 63 / 777,932 filed Mar. 26, 2025, by Young, R. J., which is hereby incorporated herein by reference in its entirety and to which priority is claimed.BACKGROUND OF THE INVENTION1. Field of the Invention

[0002] The present invention relates generally to stair treads, and, particularly, to a stair tread having an upper plate, a lower core non-moveably secured to the upper plate so as to be disposed beneath the upper plate, and a nosing extending from a forward edge of the tread. The upper plate is formed from a plurality of identical and book-matched solid wood strips of uniform thickness and length from the same solid wood. The lower core is also formed from a plurality of staves. The upper plate is made of a higher quality material than the lower core.2. Description of Related Art

[0003] Stair treads, generally speaking, have long been known and used. Typically, the stair treads include a tread member constructed of wood with a nosing affixed to a front edge of the tread.

[0004] Conventional staircases of the type found in many residential buildings are commonly fabricated from raw, construction grade materials, such as plywood, fiberboard or various other composites, and are covered with flooring materials such as carpeting to provide an attractive and comfortable exterior surface. It is also relatively common for residential staircases to be fabricated from solid hardwood, such as oak, walnut, or cherry. Hardwood staircases are generally more desirable than carpeted composite staircases and are more expensive to construct due to the higher cost of the materials involved.

[0005] In view of the above, the need exists to provide inexpensive stair treads having a look of expensive hardwood and may enhance performance and quality of stair treads.SUMMARY OF THE INVENTION

[0006] According to a first aspect of the invention, there is provided a stair tread. The stair tread comprises a rectangular base core including a plurality of elongated wooden base strips, and a rectangular upper plate disposed above the rectangular base core, the rectangular upper plate including a plurality of elongated solid wood upper plate strips of formed from the same solid wood. The rectangular upper plate is non-moveably secured to the rectangular base core so as to be disposed above the rectangular base core. The plurality of elongated wooden base strips are geometrically identical and have uniform thickness, width and length. Similarly, the plurality of elongated solid wood upper plate strips are geometrically identical and book-matched, and have uniform thickness, width and length.

[0007] According to a second aspect of the invention, there is provided a method for making a stair tread. The method comprises the steps of providing a plurality of geometrically identical elongated, rectangular wooden base strips of uniform thickness, width and length, and a plurality of geometrically identical and book-matched elongated, rectangular solid wood upper plate strips of uniform thickness, width and length formed from the same solid wood. Next, the base strips are non-moveably secured to each other so as to form a rectangular base core. After that, each of the upper plate strips is non-moveably secured to one of the base strips of the base core so that the upper plate strips are disposed above of the base strips of the base core and form a rectangular upper plate non-moveably secured on top of the base core. The base strips and the upper plate strips have identical width and length.

[0008] Other aspects of the invention, including assemblies, processes, and the like which constitute part of the invention, will become more apparent upon reading the following detailed description of the exemplary embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The accompanying drawings are incorporated in and constitute a part of the specification. The drawings, together with the general description given above and the detailed description of the exemplary embodiments and methods given below, serve to explain the principles of the invention. In such drawings:

[0010] FIG. 1 is a perspective view of from the top of a stair tread according to an exemplary embodiment of the present invention;

[0011] FIG. 2 is a perspective view of from below of the stair tread of the exemplary embodiment of the present invention;

[0012] FIG. 3 is a top view of the stair tread of the exemplary embodiment of the present invention;

[0013] FIG. 4 is a side view of the stair tread of the exemplary embodiment of the present invention.DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

[0014] Reference will now be made in detail to the exemplary embodiments and exemplary methods as illustrated in the accompanying drawings, in which the like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not necessarily limited to the specific details, representative materials and methods, and illustrative examples shown and described in connection with the exemplary embodiments and exemplary methods.

[0015] This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “horizontal,”“vertical,”“front,”“rear,”“upper”, “lower”, “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,”“downwardly,”“upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion and to the orientation relative to a vehicle body. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship. The term “integral” (or “unitary”) relates to a part made as a single part, or a part made of separate components fixedly (i.e., non-moveably) connected together. Additionally, the word “a” and “an” as used in the claims means “at least one” and the word “two” as used in the claims means “at least two”.

[0016] FIG. 1 is a perspective view of from the top of a stair tread according to an exemplary embodiment of the present invention and FIG. 2 is a perspective view of from below of the stair tread. In FIGS. 1 and 2 a book-matched stair tread 10 is provided according to an exemplary embodiment of the present invention. The term “book-matched” refers to a technique in woodworking where two adjacent slabs (or veneers) are laid side-by-side, mirroring each other, like an opened book. This creates a symmetrical, continuous pattern with veining or grain that matches, creating a seamless, high-impact aesthetic commonly used on feature walls, kitchen islands, and backsplashes.

[0017] The stair tread 10 according to the present invention is a solid wood stair tread comprising a rectangular base core 12, a rectangular upper plate 14 non-moveably secured to a stop surface of the base core 12, and a nosing 16 non-moveably secured, such as adhesively bonded, to front ends 12f and 14f of both the base core 12 and the rectangular upper plate 14, respectively, or a front edge 11F of the stair tread 10, as best shown in FIGS. 1 and 2. The rectangular base core 12 is non-moveably secured, such as adhesively bonded, to the rectangular upper plate 14 so as to be beneath the rectangular upper plate 14. As illustrated in FIGS. 1-4, each of the rectangular base cores 12 and the rectangular upper plate 14 have an identical length L and width W, but different thicknesses.

[0018] As further illustrated in FIGS. 1-3, the stair tread 10 has left and right ends 11L and 11R, respectively. The nosing 16 extends between the left and right ends 11L and 11R of the stair tread 10, and defines afront edge of the stair tread 10, as best shown in FIGS. 1, 2 and 3. In an exemplary embodiment, the stair tread 10 has a uniform length L between 36″ to 60″, a uniform width W typically between 10.5″-13″ according to the exemplary embodiment, and a uniform thickness H equal to 1.030″±0.040″, as shown in FIGS. 3 and 4.

[0019] The base core 12 is formed from a plurality (four, according to the exemplary embodiment) of geometrically identical, flat, rectangular wooden base strips 13. Each of the base strips 13 is of uniform base thickness HB (0.870″±0.040″), according to the exemplary embodiment), length L between 36″-60″ (according to the exemplary embodiment), and a uniform base width WB 11.5″±0.040″, according to the exemplary embodiment (see FIGS. 3 and 4). The base strips 13 are all made from the same wooden material, such as the red or white oak of low quality with defects according to the exemplary embodiment. The rectangular wooden base strips 13 extend between the left and right ends 11L and 11R of the stair tread 10, as shown in FIGS. 1 and 2.

[0020] The upper plate 14 is formed from a plurality (e.g., four (although other number of strips are also contemplated herein) of geometrically identical, flat, rectangular solid wood upper plate strips 15. Each of the upper plate strips 15 is of uniform thickness HS (0.160″±0.040″, according to the exemplary embodiment), a length L 36″-60″ according to the exemplary embodiment), and a uniform width WS (11.5″±0.040″, according to the exemplary embodiment), which is equal to the width WB of each of the base strips 13 (see FIGS. 3 and 4). In other words, the base strips 13 and the upper plate strips 15 have an identical length and width. Moreover, the rectangular upper plate strips 15 extend between the left and right ends 11L and 11R of the stair tread 10, as shown in FIGS. 1-3. According to the exemplary embodiment, the base core 12 and the upper plate 14 have equal number of the base and upper plate strips 13 and 15, respectively, as shown in FIGS. 1-3.

[0021] All of the base strips 13 of the base core 12 are made from the same or different wooden material, such as low quality red or white oak with defects, while all of the upper plate strips 15 are made from a slice of the same solid wood, such as high-quality book-matched red or white oak without defects, according to the exemplary embodiment. As a result, the upper plate strips 15 have a unform color pattern and grain, and the mixing of differently colored strips is avoided as may occur when a tread is manufactured from a plurality of unrelated wood strips. Moreover, the solid wood, from which the upper plate strips 15 of the rectangular upper plate 14 are made of have better quality and are more expensive wood (e.g., high quality book-matched red or white oak without defects) than the base strips 13 of the base core 12 (e.g., low quality red or white oak with defects). In other words, the adjacent upper plate strips 15 are selected so as to be book-matched, i.e., the two adjacent upper plate strips 15 are laid side-by-side, mirroring each other so as to create a symmetrical, continuous pattern with wood grain that matches, creating a seamless, high-impact aesthetic.

[0022] The base strips 13 are non-moveably secured to each other so as to form the base core 12. Specifically, according to the exemplary embodiment, the base strips 13 are adhesively bonded together (i.e., to each other) with a two-part adhesive, such as made from a urea formaldehyde, so as to form the base core 12. Urea-formaldehyde (UF) is a nontransparent, thermosetting resin produced by the condensation reaction of formaldehyde and urea. As an inexpensive adhesive, it is widely used in wood products (particleboard, MDF, plywood), molded objects, and slow-release fertilizers. UF resin provides high strength, scratch resistance, and excellent electrical insulation, though it can emit formaldehyde gas.

[0023] Alternatively, polyvinyl acetate (PVA) or the like adhesive may be used. For example, according to the exemplary embodiment, prior to assembling the stair tread 10, each of the upper plate strips 15 of the rectangular upper plate 14 is adhesively secured by polyvinyl acetate (PVA) or the like to an upper surface of one of the base strips 13 of the base core 12 so that the upper plate strips 15 of the rectangular upper plate 14 are disposed above of the base strips 13 of the base core 12.

[0024] Unlike the base strips 13, the upper plate strips 15 are each formed by sawing a stave with the result that each of the upper plate strips 15 has the same coloration, grain pattern, and visual appear as the rest of the upper plate strips 15. As a result, the upper plate 14 appears to be made from a single piece of wood, exhibiting a common color and grain pattern. While the upper plate strips 15 are made from the same piece of wood, in order to have substantially uniform color and grain, the base strips 13 may be made from different pieces of wood because color differences are masked by the overlying upper plate strips 15.

[0025] Those skilled in the art will recognize that the upper plate strips 15 of the upper plate 14 each have a thickness much less than the thickness of the base strips 13 of the base core 12. Preferably, as noted above, the upper plate strips 15 have a thickness of about 0.160 inch and the base strips 13 have a thickness of about 0.870 inch; although other dimensions are contemplated herein. The upper plate strips 15 are much thicker than a veneer, so that they may be refinished, if desired, and will not be damaged easily as may occur with a veneer. Veneer typically is about 0.060 inch thick or less, which cannot be refinished and can be easily damaged.

[0026] After each of the upper plate strips 15 has been secured to its underlying base strips 13 and the nosing 16 adhesively secured to a forward edge of the stair tread 10, the base strips 13 / upper plate strips 15 are assembled into the stair tread 10 through adhesively securing the stave B / strip S pieces in a heated press, which activates the UF adhesive to secure the base strips 13 / upper plate strips 15 together. After being removed from the press, the upper plate 14 may be profiled to the desired shape, and the stair tread 10 cut to length.

[0027] The stair tread 10 of the present invention may be a single return stair tread, a reversible return stair tread or a stair tread for open staircase.

[0028] The foregoing description of the exemplary embodiment of the present invention has been presented for the purpose of illustration in accordance with the provisions of the Patent Statutes. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. The embodiments disclosed hereinabove were chosen in order to best illustrate the principles of the present invention and its practical application to thereby enable those of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as suited to the particular use contemplated, as long as the principles described herein are followed.

[0029] This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains. Thus, changes can be made in the above-described invention without departing from the intent and scope thereof. It is also intended that the scope of the present invention be defined by the claims appended thereto.

Examples

Embodiment Construction

[0014]Reference will now be made in detail to the exemplary embodiments and exemplary methods as illustrated in the accompanying drawings, in which the like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not necessarily limited to the specific details, representative materials and methods, and illustrative examples shown and described in connection with the exemplary embodiments and exemplary methods.

[0015]This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “horizontal,”“vertical,”“front,”“rear,”“upper”, “lower”, “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,”“downwardly,”“upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing fi...

CROSS-REFERENCE TO RELATED APPLICATION AND CLAIM TO PRIORITY

[0001] This Application claims the benefit of U.S. Provisional Patent Applications Ser. No. 63 / 777,932 filed Mar. 26, 2025, by Young, R. J., which is hereby incorporated herein by reference in its entirety and to which priority is claimed.BACKGROUND OF THE INVENTION1. Field of the Invention

[0002] The present invention relates generally to stair treads, and, particularly, to a stair tread having an upper plate, a lower core non-moveably secured to the upper plate so as to be disposed beneath the upper plate, and a nosing extending from a forward edge of the tread. The upper plate is formed from a plurality of identical and book-matched solid wood strips of uniform thickness and length from the same solid wood. The lower core is also formed from a plurality of staves. The upper plate is made of a higher quality material than the lower core.2. Description of Related Art

[0003] Stair treads, generally speaking, have long been known and used. Typically, the stair treads include a tread member constructed of wood with a nosing affixed to a front edge of the tread.

[0004] Conventional staircases of the type found in many residential buildings are commonly fabricated from raw, construction grade materials, such as plywood, fiberboard or various other composites, and are covered with flooring materials such as carpeting to provide an attractive and comfortable exterior surface. It is also relatively common for residential staircases to be fabricated from solid hardwood, such as oak, walnut, or cherry. Hardwood staircases are generally more desirable than carpeted composite staircases and are more expensive to construct due to the higher cost of the materials involved.

[0005] In view of the above, the need exists to provide inexpensive stair treads having a look of expensive hardwood and may enhance performance and quality of stair treads.SUMMARY OF THE INVENTION

[0006] According to a first aspect of the invention, there is provided a stair tread. The stair tread comprises a rectangular base core including a plurality of elongated wooden base strips, and a rectangular upper plate disposed above the rectangular base core, the rectangular upper plate including a plurality of elongated solid wood upper plate strips of formed from the same solid wood. The rectangular upper plate is non-moveably secured to the rectangular base core so as to be disposed above the rectangular base core. The plurality of elongated wooden base strips are geometrically identical and have uniform thickness, width and length. Similarly, the plurality of elongated solid wood upper plate strips are geometrically identical and book-matched, and have uniform thickness, width and length.

[0007] According to a second aspect of the invention, there is provided a method for making a stair tread. The method comprises the steps of providing a plurality of geometrically identical elongated, rectangular wooden base strips of uniform thickness, width and length, and a plurality of geometrically identical and book-matched elongated, rectangular solid wood upper plate strips of uniform thickness, width and length formed from the same solid wood. Next, the base strips are non-moveably secured to each other so as to form a rectangular base core. After that, each of the upper plate strips is non-moveably secured to one of the base strips of the base core so that the upper plate strips are disposed above of the base strips of the base core and form a rectangular upper plate non-moveably secured on top of the base core. The base strips and the upper plate strips have identical width and length.

[0008] Other aspects of the invention, including assemblies, processes, and the like which constitute part of the invention, will become more apparent upon reading the following detailed description of the exemplary embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The accompanying drawings are incorporated in and constitute a part of the specification. The drawings, together with the general description given above and the detailed description of the exemplary embodiments and methods given below, serve to explain the principles of the invention. In such drawings:

[0010] FIG. 1 is a perspective view of from the top of a stair tread according to an exemplary embodiment of the present invention;

[0011] FIG. 2 is a perspective view of from below of the stair tread of the exemplary embodiment of the present invention;

[0012] FIG. 3 is a top view of the stair tread of the exemplary embodiment of the present invention;

[0013] FIG. 4 is a side view of the stair tread of the exemplary embodiment of the present invention.DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

[0014] Reference will now be made in detail to the exemplary embodiments and exemplary methods as illustrated in the accompanying drawings, in which the like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not necessarily limited to the specific details, representative materials and methods, and illustrative examples shown and described in connection with the exemplary embodiments and exemplary methods.

[0015] This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “horizontal,”“vertical,”“front,”“rear,”“upper”, “lower”, “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,”“downwardly,”“upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion and to the orientation relative to a vehicle body. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship. The term “integral” (or “unitary”) relates to a part made as a single part, or a part made of separate components fixedly (i.e., non-moveably) connected together. Additionally, the word “a” and “an” as used in the claims means “at least one” and the word “two” as used in the claims means “at least two”.

[0016] FIG. 1 is a perspective view of from the top of a stair tread according to an exemplary embodiment of the present invention and FIG. 2 is a perspective view of from below of the stair tread. In FIGS. 1 and 2 a book-matched stair tread 10 is provided according to an exemplary embodiment of the present invention. The term “book-matched” refers to a technique in woodworking where two adjacent slabs (or veneers) are laid side-by-side, mirroring each other, like an opened book. This creates a symmetrical, continuous pattern with veining or grain that matches, creating a seamless, high-impact aesthetic commonly used on feature walls, kitchen islands, and backsplashes.

[0017] The stair tread 10 according to the present invention is a solid wood stair tread comprising a rectangular base core 12, a rectangular upper plate 14 non-moveably secured to a stop surface of the base core 12, and a nosing 16 non-moveably secured, such as adhesively bonded, to front ends 12f and 14f of both the base core 12 and the rectangular upper plate 14, respectively, or a front edge 11F of the stair tread 10, as best shown in FIGS. 1 and 2. The rectangular base core 12 is non-moveably secured, such as adhesively bonded, to the rectangular upper plate 14 so as to be beneath the rectangular upper plate 14. As illustrated in FIGS. 1-4, each of the rectangular base cores 12 and the rectangular upper plate 14 have an identical length L and width W, but different thicknesses.

[0018] As further illustrated in FIGS. 1-3, the stair tread 10 has left and right ends 11L and 11R, respectively. The nosing 16 extends between the left and right ends 11L and 11R of the stair tread 10, and defines afront edge of the stair tread 10, as best shown in FIGS. 1, 2 and 3. In an exemplary embodiment, the stair tread 10 has a uniform length L between 36″ to 60″, a uniform width W typically between 10.5″-13″ according to the exemplary embodiment, and a uniform thickness H equal to 1.030″±0.040″, as shown in FIGS. 3 and 4.

[0019] The base core 12 is formed from a plurality (four, according to the exemplary embodiment) of geometrically identical, flat, rectangular wooden base strips 13. Each of the base strips 13 is of uniform base thickness HB (0.870″±0.040″), according to the exemplary embodiment), length L between 36″-60″ (according to the exemplary embodiment), and a uniform base width WB 11.5″±0.040″, according to the exemplary embodiment (see FIGS. 3 and 4). The base strips 13 are all made from the same wooden material, such as the red or white oak of low quality with defects according to the exemplary embodiment. The rectangular wooden base strips 13 extend between the left and right ends 11L and 11R of the stair tread 10, as shown in FIGS. 1 and 2.

[0020] The upper plate 14 is formed from a plurality (e.g., four (although other number of strips are also contemplated herein) of geometrically identical, flat, rectangular solid wood upper plate strips 15. Each of the upper plate strips 15 is of uniform thickness HS (0.160″±0.040″, according to the exemplary embodiment), a length L 36″-60″ according to the exemplary embodiment), and a uniform width WS (11.5″±0.040″, according to the exemplary embodiment), which is equal to the width WB of each of the base strips 13 (see FIGS. 3 and 4). In other words, the base strips 13 and the upper plate strips 15 have an identical length and width. Moreover, the rectangular upper plate strips 15 extend between the left and right ends 11L and 11R of the stair tread 10, as shown in FIGS. 1-3. According to the exemplary embodiment, the base core 12 and the upper plate 14 have equal number of the base and upper plate strips 13 and 15, respectively, as shown in FIGS. 1-3.

[0021] All of the base strips 13 of the base core 12 are made from the same or different wooden material, such as low quality red or white oak with defects, while all of the upper plate strips 15 are made from a slice of the same solid wood, such as high-quality book-matched red or white oak without defects, according to the exemplary embodiment. As a result, the upper plate strips 15 have a unform color pattern and grain, and the mixing of differently colored strips is avoided as may occur when a tread is manufactured from a plurality of unrelated wood strips. Moreover, the solid wood, from which the upper plate strips 15 of the rectangular upper plate 14 are made of have better quality and are more expensive wood (e.g., high quality book-matched red or white oak without defects) than the base strips 13 of the base core 12 (e.g., low quality red or white oak with defects). In other words, the adjacent upper plate strips 15 are selected so as to be book-matched, i.e., the two adjacent upper plate strips 15 are laid side-by-side, mirroring each other so as to create a symmetrical, continuous pattern with wood grain that matches, creating a seamless, high-impact aesthetic.

[0022] The base strips 13 are non-moveably secured to each other so as to form the base core 12. Specifically, according to the exemplary embodiment, the base strips 13 are adhesively bonded together (i.e., to each other) with a two-part adhesive, such as made from a urea formaldehyde, so as to form the base core 12. Urea-formaldehyde (UF) is a nontransparent, thermosetting resin produced by the condensation reaction of formaldehyde and urea. As an inexpensive adhesive, it is widely used in wood products (particleboard, MDF, plywood), molded objects, and slow-release fertilizers. UF resin provides high strength, scratch resistance, and excellent electrical insulation, though it can emit formaldehyde gas.

[0023] Alternatively, polyvinyl acetate (PVA) or the like adhesive may be used. For example, according to the exemplary embodiment, prior to assembling the stair tread 10, each of the upper plate strips 15 of the rectangular upper plate 14 is adhesively secured by polyvinyl acetate (PVA) or the like to an upper surface of one of the base strips 13 of the base core 12 so that the upper plate strips 15 of the rectangular upper plate 14 are disposed above of the base strips 13 of the base core 12.

[0024] Unlike the base strips 13, the upper plate strips 15 are each formed by sawing a stave with the result that each of the upper plate strips 15 has the same coloration, grain pattern, and visual appear as the rest of the upper plate strips 15. As a result, the upper plate 14 appears to be made from a single piece of wood, exhibiting a common color and grain pattern. While the upper plate strips 15 are made from the same piece of wood, in order to have substantially uniform color and grain, the base strips 13 may be made from different pieces of wood because color differences are masked by the overlying upper plate strips 15.

[0025] Those skilled in the art will recognize that the upper plate strips 15 of the upper plate 14 each have a thickness much less than the thickness of the base strips 13 of the base core 12. Preferably, as noted above, the upper plate strips 15 have a thickness of about 0.160 inch and the base strips 13 have a thickness of about 0.870 inch; although other dimensions are contemplated herein. The upper plate strips 15 are much thicker than a veneer, so that they may be refinished, if desired, and will not be damaged easily as may occur with a veneer. Veneer typically is about 0.060 inch thick or less, which cannot be refinished and can be easily damaged.

[0026] After each of the upper plate strips 15 has been secured to its underlying base strips 13 and the nosing 16 adhesively secured to a forward edge of the stair tread 10, the base strips 13 / upper plate strips 15 are assembled into the stair tread 10 through adhesively securing the stave B / strip S pieces in a heated press, which activates the UF adhesive to secure the base strips 13 / upper plate strips 15 together. After being removed from the press, the upper plate 14 may be profiled to the desired shape, and the stair tread 10 cut to length.

[0027] The stair tread 10 of the present invention may be a single return stair tread, a reversible return stair tread or a stair tread for open staircase.

[0028] The foregoing description of the exemplary embodiment of the present invention has been presented for the purpose of illustration in accordance with the provisions of the Patent Statutes. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. The embodiments disclosed hereinabove were chosen in order to best illustrate the principles of the present invention and its practical application to thereby enable those of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as suited to the particular use contemplated, as long as the principles described herein are followed.

[0029] This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains. Thus, changes can be made in the above-described invention without departing from the intent and scope thereof. It is also intended that the scope of the present invention be defined by the claims appended thereto.

Examples

Embodiment Construction

[0014]Reference will now be made in detail to the exemplary embodiments and exemplary methods as illustrated in the accompanying drawings, in which the like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not necessarily limited to the specific details, representative materials and methods, and illustrative examples shown and described in connection with the exemplary embodiments and exemplary methods.

[0015]This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “horizontal,”“vertical,”“front,”“rear,”“upper”, “lower”, “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,”“downwardly,”“upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing fi...

Claims

1. A stair tread comprising:a base core including a plurality of geometrically identical elongated wooden base strips of uniform thickness, width and length; andan upper plate disposed above the base core, the upper plate including a plurality of geometrically identical and book-matched elongated solid wood upper plate strips of uniform thickness, width and length formed from a same solid wood, wherein the upper plate is non-moveably secured to the base core so as to be disposed above the base core.

2. The stair tread as defined in claim 1, further comprising a front nosing non-moveably secured to front ends of both the base core and the upper plate.

3. The stair tread as defined in claim 1, wherein the base core is adhesively bonded to the upper plate so as to be disposed beneath the upper plate.

4. The stair tread as defined in claim 1, wherein the elongated wooden base strips are non-moveably secured to each other so as to form the base core.

5. The stair tread as defined in claim 4, wherein the elongated wooden base strips are adhesively bonded to each other so as to form the base core.

6. The stair tread as defined in claim 1, wherein each of the elongated solid wood upper plate strips is non-moveably secured to one of the elongated wooden base strips so as to form the upper plate.

7. The stair tread as defined in claim 6, wherein each of the upper plate strips is adhesively bonded to one of the base strips so as to form the upper plate.

8. The stair tread as defined in claim 1, wherein the elongated wooden base strips of the elongated wooden base core are thicker than the upper plate strips of the upper plate.

9. The stair tread as defined in claim 1, wherein the upper plate strips of the upper plate are made of a higher quality wood than the elongated wooden base strips of the base core.

10. The stair tread as defined in claim 9, wherein the upper plate strips of the upper plate are made of hardwood material.

11. The stair tread as defined in claim 1, wherein the two adjacent upper plate strips of the upper plate mirror each other to creates a symmetrical, continuous pattern with wood grain that matches.

12. The stair tread as defined in claim 1, wherein the base core and the upper plate are rectangular.

13. A method for making a stair tread, comprisingproviding a plurality of geometrically identical elongated, rectangular wooden base strips of uniform thickness, width and length;providing a plurality of geometrically identical and book-matched elongated, rectangular solid wood upper plate strips of uniform thickness, width and length formed from the same solid wood;non-moveably securing the elongated wooden base strips are to each other so as to form a rectangular base core; andnon-moveably securing each of the upper plate strips to one of the elongated wooden base strips of the base core so that the upper plate strips are disposed above of the elongated wooden base strips of the base core and form a rectangular upper plate non-moveably secured on top of the base core, wherein the elongated solid wood upper strips and the upper plate strips having identical width and length.

14. The method as defined in claim 13, wherein the step of non-moveably securing the elongated wooden base strips are to each other includes the step of adhesively bonding the elongated wooden base strips are to each other, and the step of non-moveably securing each of the upper plate strips to one of the elongated wooden base strips includes the step of adhesively bonding each of the upper plate strips to one of the elongated wooden base strips.

15. The method as defined in claim 13, further comprising:providing a front nosing; andadhesively securing the front nosing to front ends of both the rectangular base core and the rectangular upper plate.

16. The method as defined in claim 13, wherein the elongated wooden base strips of the base core are thicker than the upper plate strips of the upper plate.

17. The method as defined in claim 13, wherein the elongated solid wood upper plate strips of the upper plate are made of a higher quality wood than the elongated wooden base strips of the base core.

18. The method as defined in claim 17, wherein the elongated solid wood upper plate strips are made of hardwood material.

19. The method as defined in claim 18, wherein each of the elongated solid wood upper plate strips is non-moveably secured to one of the elongated wooden base strips so that the two adjacent elongated solid wood upper plate strips of the upper plate mirror each other to creates a symmetrical, continuous pattern with wood grain that matches.

20. A structure comprising:a base core including a plurality of elongated wooden base strips length; andan upper plate comprising book-matched elongated solid wood upper plate strips of uniform thickness, width and length formed from a slice of a same solid wood, and which is adhesively secured to a top surface of the base core.

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