Stair bracket and method for connecting a plurality of stair brackets to a supporting member

Abstract

A stair bracket includes a body, tread and riser flanges extending orthogonally from the body, a tread measuring portion, and pluralities of tread and riser apertures. The body, which has first, second and third body ends, defines a tread side that extends from the first body end to the second body end, and a riser side that extends from the first body end to the third body end. The tread flange is connected to the body at the tread side, and has first and second tread flange ends. The tread measuring portion is graduated and is disposed at the second body end. The riser flange is connected to the body at the riser side, and has first and second riser flange ends. A distance between the first and second riser flange ends is greater than 75% of a distance between the first and second body ends.

Description

STAIR BRACKET AND METHOD FOR CONNECTINGA PLURALITY OF STAIR BRACKETS TO A SUPPORTING MEMBERCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to United States Provisional Patent Application No. 63 / 698,738, filed September 25, 2024 and United States Provisional Patent Application No. 63 / 865,815 filed August 18, 2025, both of which are incorporated by reference herein in their entirety.TECHNICAL FIELD

[0002] The present technology relates to stair construction, more specifically to stair brackets and methods for connecting a plurality of stair brackets to a supporting member.BACKGROUND

[0003] Traditional methods of constructing stairs involve cutting 2”xl2” (5.08 cm x 30.48 cm) lumber into sawtooth shapes with desired tread depths and riser heights, which can be labor-intensive and time-consuming. Additionally, measuring and cutting the lumber are tasks that are generally performed by skilled workers. These traditional methods, particularly if mistakes are made, can therefore lead to waste. Also, cutting 2”xl2” (5.08 cm x 30.48 cm) lumber can reduce its load bearing capacity.

[0004] Conventional stair brackets used to avoid cutting lumber into sawtooth shapes exist. However, they can be cumbersome to install and may not be able to sustain loads as high as the traditional sawtooth-shaped lumber.

[0005] There is a desire for a technology that can overcome at least some of the abovedescribed drawbacks, notably by providing a stair bracket that can assist in easing and accelerating the process of constructing stairs, while limiting waste and while being able to provide options for different riser height and tread depth.SUMMARY

[0006] It is an object of the present technology to improve at least some of the inconveniences present in the prior art.

[0007] According to one aspect of the present technology, there is provided a stair bracket. The stair bracket has a body, a tread flange, a tread measuring portion, a riser flange, a plurality of tread apertures and a plurality of riser apertures. The body has a first body end, a second body end and a third body end, and the body defines a tread side extending from the first body end to the second body end, and a riser side extending from the first body end to the third body end, the riser side being orthogonal to the tread side. The tread flange is connected to the body at the tread side, has a first tread flange end and a second tread flange end, and extends orthogonally away from the body. Part of the tread flange extends along the tread side between the first tread flange end and the second tread flange end. The tread measuring portion is disposed at the second body end, and is graduated. The riser flange is connected to the body at the riser side, has a first riser flange end and a second riser flange end, and extends orthogonally away from the body. Part of the riser flange extends along the riser side between the first riser flange end and the second riser flange end. A distance between the first riser flange end and the second riser flange end is greater than 75% of a distance between the first body end and the third body end.

[0008] In some embodiments, at least one of the first tread flange end is generally aligned with the first body end, and the second tread flange end is generally aligned with the second body end.

[0009] In some embodiments, at least one of the first riser flange end is generally aligned with the first body end, and the second riser flange end is generally aligned with the third body end.

[0010] In some embodiments, the tread flange and the riser flange extend orthogonally away from the body in a same direction.

[0011] In some embodiments, the stair bracket further includes at least one of tread connecting apertures defined in the tread flange, and riser connecting apertures defined in the riser flange.

[0012] In some embodiments, the tread measuring portion is connected to the body.

[0013] In some embodiments, the tread measuring portion is selectively connected to the body.

[0014] In some embodiments, the tread measuring portion is connected to the body via an adhesive.

[0015] In some embodiments, the tread measuring portion has a free end, and the second body end is between the first body end and the free end.

[0016] In some embodiments, the tread measuring portion is foldable between an in-use configuration, in which the second body end is between the first body end and the free end of the tread measuring portion, and a storage configuration, in which the free end of the tread measuring portion is between the first body end and the second body end.

[0017] In some embodiments, part of the tread measuring portion can fold about the second body end.

[0018] In some embodiments, the tread measuring portion is flexible.

[0019] In some embodiments, a thickness of the tread measuring portion is less than 1 mm.

[0020] In some embodiments, a tread edge is defined by the body and the tread flange, and graduations of the tread measuring portion extend from the tread edge.

[0021] In some embodiments, the stair bracket further includes a riser measuring portion disposed at the second riser flange end, the riser measuring portion being graduated.

[0022] In some embodiments, the riser measuring portion is connected to the riser flange.

[0023] In some embodiments, the riser measuring portion is selectively connected to the riser flange.

[0024] In some embodiments, the riser measuring portion is connected to the riser flange via an adhesive.

[0025] In some embodiments, one end of the riser measuring portion is aligned with the third body end.

[0026] In some embodiments, the riser edge is defined by the body and the riser flange, and ends of graduations of the riser measuring portion are aligned with the riser edge.

[0027] In some embodiments, a plurality of tread apertures is defined on the body, the plurality of tread apertures being positioned between the first tread flange end and the second tread flange end, and a plurality of riser apertures is defined on the body, the plurality of riser apertures being positioned between the first riser flange end and the second riser flange end.

[0028] In some embodiments, the body includes a tread supporting portion, a tread connecting portion, a riser supporting portion and a riser connecting portion. The tread supporting portion and the tread connecting portion extend along and away from the tread side, the tread connecting portion extending further away from the tread side than the tread supporting portion, and the plurality of tread apertures being defined on the tread connecting portion. The riser supporting portion and the riser connecting portion extend along and away from the riser side, the riser connecting portion extending further away from the riser side than the riser supporting portion, and the plurality of riser apertures being defined on the riser connecting portion.

[0029] In some embodiments, the body generally defines an L-shape.

[0030] In some embodiments, the body, the tread flange and the riser flange are unitary.

[0031] According to another aspect of the present technology, there is provided a method for connecting a plurality of stair brackets to supporting member. The method includes connecting a first stair bracket of the plurality of stair brackets to the supporting membersuch that with the supporting member being in a mounting position, a tread flange of the first stair bracket is generally horizontal, and a riser flange of the first stair bracket is generally vertical.

[0032] The method further includes positioning, relative to the first stair bracket, a second stair bracket of the plurality of stair brackets on the supporting member, at least part of a riser flange of the second stair bracket extending over a tread measuring portion of the first stair bracket such that the tread measuring portion of the first stair bracket is laterally between the second stair bracket and the supporting member. With the supporting member being in a mounting position, a tread flange of the second stair bracket is generally horizontal, and a riser flange of the second stair bracket is generally vertical. The method further includes connecting the second stair bracket to the supporting member.

[0033] In the context of the present disclosure, terms related to spatial orientation when referring to stairs and components related thereto as they would be understood by someone standing in front of the stairs.

[0034] In the context of the present specification, unless expressly provided otherwise, the words “first”, “second”, “third”, etc. have been used as adjectives only for the purpose of allowing for distinction between the nouns that they modify from one another, and not for the purpose of describing any particular relationship between those nouns.

[0035] It must be noted that, as used in this specification, the singular form “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.

[0036] As used herein, the term “about” and “generally” in the context of a given value or range refers to a value or range that is within 20%, preferably within 10%, and more preferably within 5% of the given value or range.

[0037] As used herein, the term “and / or” is to be taken as specific disclosure of each of the two specified features or components with or without the other. For example, “A and / or B” is to be taken as specific disclosure of each of (i) A, (ii) B and (iii) A and B, just as if each is set out individually herein.

[0038] Embodiments of the present technology each have at least one of the above- mentioned objects and / or aspects, but do not necessarily have all of them. It should be understood that some aspects of the present technology that have resulted from attempting to attain the above-mentioned object may not satisfy this object and / or may satisfy other objects not specifically recited herein.

[0039] Additional and / or alternative features, aspects, and advantages of embodiments of the present technology will become apparent from the following description and the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0040] For a better understanding of the present technology, as well as other aspects and further features thereof, reference is made to the following description which is to be used in conjunction with the accompanying drawings, where:

[0041] Figure 1 is a perspective view taken from a bottom, rear, right side of a left stair bracket according to an embodiment of the present technology;

[0042] Figure 2 is a perspective view taken from a top, front, right side of the left stair bracket of Figure 1;

[0043] Figure 3 is right side elevation view of the left stair bracket of Figure 1;

[0044] Figure 4 is a rear elevation view of the left stair bracket of Figure 1;

[0045] Figure 5 is a left side elevation view of the left stair bracket of Figure 1;

[0046] Figure 6 is a perspective view taken from a top, front, left side of the left stair bracket of Figure 1;

[0047] Figure 7 is a perspective view taken from a bottom, rear, left side of the left stair bracket of Figure 1;

[0048] Figure 8 is a perspective view taken from a top, front, left side of a right stair bracket according to an embodiment of the present technology;

[0049] Figure 9 is a perspective view taken from a top, rear, left side of a left supporting member having the left stair brackets of Figure 1 connected thereto and a right supporting member having the right stair brackets of Figure 8 connected thereto;

[0050] Figure 10 is a perspective view taken from a top, rear, right side of the left supporting member and the left stair brackets of Figure 9, with some features, such as the left supporting member, being shown in transparency;

[0051] Figure 11 is right side elevation view of the left supporting member and the left stair brackets of Figure 10;

[0052] Figure 12A is a right side elevation view of the left supporting member and the left stair brackets of Figure 10 having a tread and a riser connected to the left stair brackets;

[0053] Figure 12B is a right side elevation view of the left supporting member and the left stair brackets of Figure 10 having a tread and a riser according to alternative embodiments of the present technology connected to the left stair brackets;

[0054] Figure 13 is a perspective view taken from a top, rear, left side of the left and right supporting members of Figure 9 and the tread and riser of Figure 12A;

[0055] Figure 14 is a perspective view taken from a top, rear, left side of the left and right supporting members of Figure 9 and the tread and riser of Figure 13, with two additional left stair brackets and two additional right stair brackets being connected to the left and right supporting members respectively; and

[0056] Figure 15 is a perspective view taken from a top, rear, left side of a right stair bracket according to an alternative embodiment of the present technology.

[0057] Unless otherwise noted, the Figures may not be drawn to scale.DETAILED DESCRIPTION

[0058] The present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated inthe drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including", "comprising", or "having", "containing", "involving" and variations thereof herein, is meant to encompass the items listed thereafter as well as, optionally, additional items. In the following description, the same numerical references refer to similar elements.

[0059] A left stair bracket 50 according to an embodiment of the present technology is shown in Figures 1 to 7. A right stair bracket 52 is shown in Figure 8, and will be described in greater detail below.

[0060] Referring to Figures 1 to 7, the left stair bracket 50 includes a body 60, a tread flange 62 and a riser flange 64, both of which are connected to the body 60, a tread measuring portion 66 connected to the body 60 and a riser measuring portion 68 disposed on the riser flange 64.

[0061] The body 60 has a body end 70 (which may be referred to as a rear top body end 70), a body end 72 (which may be referred to as a front top body end 72) and a body end 74 (which may be referred to as a rear bottom body end 74). The body ends 70, 72, 74 are positioned relative to one another such that they correspond to the vertices of a right-angled triangle. The body 60 has a tread side 76 that extends between the body ends 70, 72 and a riser side 78 that extends between the body ends 70, 74. The tread side 76 and the riser side 78 are generally orthogonal to one another. The body 60 further has an abutting surface 79 (Figures 5 to 7). As will be described below, the abutting surface 79 is configured to abut a supporting member.

[0062] The body 60 has a tread supporting portion 80, a tread connecting portion 82, a riser supporting portion 84 and a riser connecting portion 86, all of which are in part schematically delimited by dotted lines in Figures 1, 3 and 5. It is understood that the body 60 may have fewer or additional portions in other embodiments and / or that the portions of the body 60 may be delimited and / or shaped differently.

[0063] The tread supporting portion 80 extends along part of the tread side 76, from the body end 70 toward the body end 72. The tread supporting portion 80 has a trapezoidal shape, that is oriented such that a distance DI (Figure 3) is uniform along most of the tread side 76. It is contemplated that the shape of the tread supporting portion 80 may vary without departing from the scope of the present technology.

[0064] The tread connecting portion 82 extends from the tread supporting portion 80 to the body end 72. The tread connecting portion 82 also has a pentagonal shape, and is oriented such that a distance D2 (Figure 3), which is measured from the tread flange 62 to an orthogonally furthermost point of the tread connecting portion 82, varies along part of the distance between the tread supporting portion 80 and the body end 72. The tread connecting portion 82 defines nine tread apertures 83. It is contemplated that the number of tread apertures 83 may vary. As will be described below, the tread apertures 83 are configured to receive fasteners therethrough for connecting the stair bracket 50 to a supporting member. The nine tread apertures 83 are all spaced from one another, and are all spaced from the tread side 76 and the body end 72 differently, which enables the stair bracket 50 to be connected to the supporting member in different ways. For example, if two of the nine tread apertures 83 are offset from the supporting member, the other seven tread apertures 83 may be used. Thus, the tread apertures 83 enable, in part, the stair bracket 50 to provide a step of different tread depth. Additionally, using two tread apertures 83 that are relatively far away from one another (e.g., generally opposite tread apertures 83) can increase a stability of the stair bracket 50, such that the stair bracket 50 is less likely to move with respect to the supporting member when a load is applied on the stair bracket 50. The shape of the tread connecting portion 82 being enlarged enables the tread apertures 83 to be further spaced apart from one another. It will also be noted that using two tread apertures 83 that are longitudinally and vertically spaced from one another can further increase stability.

[0065] The riser supporting portion 84 extends along part of the riser side 78, from the body end 70 toward the body end 74. The riser supporting portion 84 has a trapezoidal shape that is oriented such that a distance D3 (Figure 3) is uniform along most of the riserside 78. It is contemplated that the shape of the riser supporting portion 84 may vary from one embodiment to another.

[0066] The riser connecting portion 86 extends from the riser supporting portion 84 to the body end 74. The riser connecting portion 86 also has a pentagonal shape, and is oriented such that a distance D4 (Figure 3), which is measured from the riser flange 64 to an orthogonally furthermost point of the riser connecting portion 86, varies along part of the distance between the riser supporting portion 84 and the body end 74. The riser connecting portion 86 defines nine tread apertures 87. It is contemplated that the number of riser apertures 87 may vary. As will be described below, the riser apertures 87 are configured to receive fasteners therethrough to connect a supporting member. The nine riser apertures 87 are all spaced from one another, and are all spaced from the riser side 78 and the body end 74 differently, which enables the stair bracket 50 to be connected to the supporting member in different ways. Thus, the riser apertures 87 enable, in part, the stair bracket 50 to provide a step of different riser heights. Similar to the tread apertures 83, using two riser apertures 87 that are relatively far away from one another can also increase the stability of the stair bracket 50 with respect to the supporting member. The shape of the riser connecting portion 86 being enlarged enables the riser apertures 87 to be further spaced from one another.

[0067] As best seen in Figure 3, the body 60 generally defines an L-shape, with the tread side 76 being longer than the riser side 78. Specifically, the tread side 76 measures 10 inches (about 25.40 cm) whereas the riser side 78 measures 8 inches (about 20.32 cm). In other embodiments, the tread side 76 and / or the riser side 78 may measure 6, 7, 9 or 11 inches (15.24 cm, 17.78 cm, 22.86 cm or 27.94 cm). In some embodiments, the body 60 may be symmetrical about a plane bisecting the right angle formed between the body end 72, the body end 70 and the body end 74.

[0068] The tread flange 62 is connected to the body 60 at the tread side 76, and extends generally orthogonally therefrom. The tread flange 62 has a tread flange end 90 and a tread flange end 92. In the present embodiment, the tread flange end 90 is generally aligned with the body end 70, and the tread flange end 92 is generally aligned with the body end 72. It is contemplated that in other embodiments, the tread flange 62 could be configureddifferently, such as, for example, by having the tread flange end 90 be offset from the body end 70 and / or by having the tread flange end 92 be offset from the body end 72. The tread flange 62 defines a plurality of tread connecting apertures 63. The tread connecting apertures 63 are configured to receive fasteners therethrough for connecting a tread to the stair bracket 50. The tread flange 62 reinforces the structural integrity of the stair bracket 50.

[0069] The riser flange 64 is connected to the body 60 at the riser side 78, and extends generally orthogonally therefrom, in the same direction as the tread flange 62. The riser flange 64 has a riser flange end 100 and a riser flange end 102. In the present embodiment, the riser flange end 100 is generally aligned with the body end 70, and the riser flange end 102 is generally aligned with the body end 74 such that the riser flange 64 extends along an entirety of the riser side 78. It is contemplated that in other embodiments, the riser flange 64 could be configured differently, such as, for example, by having the riser flange end 100 be offset from the body end 70 and / or by having the riser flange end 102 be offset from the body end 74. Thus, it is contemplated that in some embodiments, the riser flange 64 may be configured such that a distance between the riser flange ends 100, 102 is greater than 90% of a distance between the body ends 70, 74. In other embodiments, the riser flange 64 may be configured such that the distance between the riser flange ends 100, 102 is greater than 80% of the distance between the body ends 70, 74. In other embodiments, the riser flange 64 may be configured such that the distance between the riser flange ends 100, 102 is greater than 75% of the distance between the body ends 70, 74. The riser flange 64 extending along at least 75% of the riser side 78 reinforces the structural integrity of the stair bracket 50, and can enable it to sustain greater loads while connected to a supporting member. The riser flange 64 defines a plurality of riser connecting apertures 65. The riser connecting apertures 65 are configured to receive fasteners therethrough for connecting a riser to the stair bracket 50.

[0070] The body 60, the tread flange 62 and the riser flange 64 are unitary. More specifically, the body 60, the tread flange 62 and the riser flange 64 are made of a 16 gauge steel sheet metal that has been bent to form the tread and riser flanges 62, 64. It is contemplated that the body 60, the tread flange 62 and the riser flange 64 could be madeof another material and / or have a different thickness. For example, in Figure 15, a right stair bracket 52’ is shown. Features of the right stair bracket 52’ similar to those of the stair bracket 50 have been labeled with the same reference numerals and will not be re-described in detail herewith. The body 60 of the right stair bracket 52’ is made of a composite material and extends laterally to have a thickness of about 1.5 inches (about 3.81 cm). In this embodiment, the tread flange 62 is an upper surface of the body 60, and the riser flange 64 is rear surface of the body 60. The body 60 defines inclined apertures 69’. The inclined apertures 69’ are configured to receive fasteners for connecting risers and treads to the stair bracket 52’. It is contemplated that in other embodiments, the body 60, the tread flange 62 and the riser flange 64 may be made of two or more parts connected to one another. For example, the body 60, the tread flange 62 and the riser flange 64 could be three distinct parts that are made of wood, and that are glued to one another. In yet other embodiments, one or more of the body 60, the tread flange 62 and the riser flange 64 may be made of composite material.

[0071] Referring to Figures 1, 4 and 7, the riser measuring portion 68 is disposed on the riser flange 64, at the riser flange end 102. More specifically, the riser measuring portion 68 is disposed such that an end of the riser measuring portion 68 is aligned with the riser flange end 102 (and thus with the body end 74). The riser measuring portion 68 is for adjusting the riser height (rise) of a step to desired rise when installing the stair bracket 50 to a supporting member. To this end, the riser measuring portion 68 is graduated. A starting point of the graduation is at a top of the tread flange 62, such that the top of the tread flange 62 corresponds to a riser height of zero and the end of the riser measuring portion 68 corresponds to the maximum riser height (which can vary from one embodiment to another, depending on the size of the riser side 78). As shown in the accompanying Figures, only some of the graduations are shown. It is contemplated that in some embodiments, all the graduations from a riser height of zero to a maximum riser height may be shown. The graduations are positioned near the abutting surface 79. More precisely, the graduations are positioned so as to extend from a riser edge 91 defined by the body end 70 and the riser flange 64 (i.e., ends of the graduations are generally aligned with the intersection of the riser flange 64 and the body 60). The graduations are therefore positioned such that, when the abutting surface 79 abuts the supporting member, the graduations extend generallyorthogonally away from the supporting member, which can facilitate reading of the graduations . This can make it easier to precisely position the stair bracket 50 on the supporting member. A riser variation zone is provided by the stair bracket 50. The riser variation zone can be said to correspond to the range of adjustment that the stair bracket 50 can provide for a rise height. In the present embodiment, the riser variation zone extends along the shown graduations. However, the present technology enables the riser variation zone to extend entirely between the body ends 70, 72, such that graduations could be shown along all of the riser flange 64. In some embodiments, a minimum riser height may be designated. The riser flange 64 extending along all of the riser variation zone provided by the stair bracket 50 assists in reinforcing the structural integrity of the stair bracket 50, and can enable it to sustain higher loads.

[0072] The riser measuring portion 68 is a graduated sticker, such that the riser measuring portion 68 is connected to the riser flange 64 via an adhesive. In some embodiments, the riser measuring portion 68 may be selectively connected to the riser flange 64. The graduated sticker may be made of paper to minimize costs, or may be made of tear-resistant material such as plastic. It is contemplated that the riser measuring portion 68 may be disposed on the riser flange 64 differently. For example, in some embodiments, the riser measuring portion 68 may be etched, engraved, or marked on the riser flange 64. In yet other embodiments, the riser measuring portion 68 may extend beyond the body end 74. In some embodiments, the riser measuring portion 68 could be an extension of the riser flange 64. It is also contemplated that in some embodiments, the riser measuring portion 68 may be omitted from the riser side 78. In some embodiments, the riser measuring portion 68 may be disposed on the riser supporting portion 84 and / or on the riser connecting portion 86.

[0073] Referring to Figures 1, 2 and 5 to 7, the tread measuring portion 66 is disposed on the body 60, near the tread flange 62. More specifically, the tread measuring portion 66 is disposed on the tread connecting portion 82, such that the tread measuring portion 66 partially extends beyond the tread flange end 92 (and thus beyond the body end 72). In some embodiments, the tread measuring portion 66 is a non- structural component, such as a thin ruler that is connected to the body 60. The tread measuring portion 66 is for adjustinga tread depth (run) of a step to the desired run when installing the stair bracket 50 to the supporting member. To this end, the tread measuring portion 66 is a graduated ruler. A starting point of the graduation is at the rear of the riser flange 64, such that the rear of the riser flange 64 corresponds to a tread depth (run) of zero and the end of the tread measuring portion 66 extending beyond the tread flange end 92 corresponds to the maximum tread length (which can vary from one embodiment to another, depending on the size of the tread side 76 and the size of tread measuring portion 66). The graduations are positioned so as to extend from a tread edge 93 defined by the body end 70 and the tread flange 62 (i.e., ends of the graduations are generally aligned with the intersection of the tread flange 62 and the body 60). Thus, the graduations can be read against a supporting member near the tread flange 62. As will be described below, this can make it easier to precisely position the stair bracket 50 relative to the supporting member and relative to other stair brackets 50. A tread variation zone is provided by the stair bracket 50. The tread variation zone can be said to correspond to the range of adjustment that the stair bracket 50 can provide for a tread depth. In the present embodiment, the tread variation zone extends along the tread measuring portion 66 (i.e., along the graduated ruler). In the present embodiment, a distance between the body end 72 and a free end of the tread measuring portion 66 could be configured to measure less than or equal to one inch (2.54 cm), such that the tread variation zone could measure less than or equal to one inch. This can assist in limiting back tread overhang at no more than a tread nosing. It is contemplated that the distance between the body end 72 and a free end of the tread measuring portion 66 could measure more or less than one inch.

[0074] The tread measuring portion 66 is a graduated sticker, such that the tread measuring portion 66 is connected to the body 60 via an adhesive. In some embodiments, the tread measuring portion 66 may be selectively connected to the tread flange 62. The graduated sticker may be made of paper to minimize costs, or may be made of tear-resistant material such as plastic.

[0075] Additionally, the tread measuring portion 66 is flexible and very thin. Specifically, the tread measuring portion 66 has a thickness of less than about 1 mm. In some embodiments, the tread measuring portion 66 may have a thickness of about 0.20mm. Inother embodiments, the tread measuring portion 66 may have a thickness of about 0.10mm. In other embodiments, the tread measuring portion 66 may have a thickness of about 0.05mm. In other embodiments, the tread measuring portion 66 may be resiliently deformable. The tread measuring portion 66 is foldable about the body end 72 between an in-use configuration (Figures 1 to 5) and a storage configuration (Figures 6 and 7).

[0076] When the tread measuring portion 66 is in the in-use configuration, the tread measuring portion 66 is positioned to be generally parallel to the body 60, and since the tread measuring portion 66 extends beyond the body end 72, it can be said that the body end 72 is disposed between the body end 70 and a free end of the tread measuring portion 66.

[0077] When the tread measuring portion 66 is in the storage configuration, the tread measuring portion 66 is folded abut the body end 72, such that the free end of the tread measuring portion 66 is disposed between the body end 70 and the body end 72. When the tread measuring portion 66 is in the storage configuration, two or more stair brackets 50 can be stacked without causing damage to the tread measuring portion 66, thereby facilitating transportation thereof. Preventing damage to the tread measuring portion 66 can reduce installation misalignments when connecting the stair brackets 50 to supporting members.

[0078] Referring now to Figure 8, the right stair bracket 52 is a mirror image of the left stair bracket 50, and thus will not be re-described in detail herewith. Features of the right stair bracket 52 similar to those of the left stair bracket 50 have been labeled with the same reference numerals. The right stair bracket has the body 60, the tread flange 62, the riser flange 64, the tread measuring portion 66 and the riser measuring portion 68.

[0079] Referring to Figures 9 to 14, a method for constructing stairs and a method for connecting the left and right stair brackets 50, 52 to left and right supporting members 130, 132 will be described. The left and right supporting members 130, 132 are 2x12 lumber, but it is contemplated that they could be made of other material.

[0080] The method begins by connecting a plurality of the left stair brackets 50 to the left supporting member 130 and by connecting a plurality of the right stair brackets 52 to the right supporting member 132. As the steps to connect the plurality of left stair brackets 50 to the left supporting member 130 are similar to the steps to connect the plurality of right stair brackets 52 to the right supporting member 132, only the steps for connecting the left stair brackets 50 to the left supporting member 130 will be described herewith.

[0081] The bottommost stair bracket 50, henceforth referred to as stair bracket 50a, is connected to the supporting member 130 by causing the abutting surface 79 of the stair bracket 50a to abut the supporting member 130, and by precisely positioning the stair bracket 50a on the supporting member 130 via the tread measuring portion 66 and via the riser measuring portion 68. It will be noted that positioning the stair bracket 50a on the supporting member 130 is facilitated by the disposition of the graduations of the tread measuring portion 66 relative to the supporting member 130. Once properly positioned, the stair bracket 50a can be connected to the supporting member 130 by inserting two fasteners 140 through two tread apertures 83. As mentioned above, the two tread apertures 83 may be chosen to be spaced from one another so as to increase the stability of the stair bracket 50a relative to the supporting member 130. The tread measuring portion 66 extends along a surface of the supporting member 130. As will be described below, and as shown in Figures 9 to 12A, the stair bracket 50a may be partially cut to conform to a desired riser height.

[0082] It will be appreciated that the stair bracket 50a is oriented, relative to the supporting member 130, such that when the supporting member 130 is in its final position (shown in the accompanying Figures), the tread flange 62 is generally horizontal, and the riser flange 64 is generally vertical.

[0083] The method then continues by positioning, relative to the stair bracket 50a, another left stair bracket 50b. As best seen in Figures 10 to 12A, part of the stair bracket 50b extends over the tread measuring portion 66 of the stair bracket 50a, such that the tread measuring portion 66 of the stair bracket 50a is disposed laterally between the supporting member 130 and the abutting surface 79 of the stair bracket 50b (i.e., between the supporting member130 and the riser connecting portion 86, and in some instances, between the supporting member 130 and the riser supporting portion 84).

[0084] Due to the tread measuring portion 66 having a very small thickness, this overlap does not cause any misalignment issues of the overlapping bracket. More specifically, due to the presence of the tread measuring portion 66, a gap defined between the abutting surface 79 and the supporting member 130 is very small. In some instances, due to the very small thickness of the tread measuring portion 66, it can be said that the there is no gap between the abutting surface 79 and the supporting member 130. Thus, the tread measuring portion 66 can be said to be generally aligned with a surface of the supporting member 130, and the riser measuring portion 68 can be said to be spaced from the surface of the supporting member 130 by the thickness of the tread measuring portion 66, which can be as little as 0.2mm. This results in minimizing torsional loads that the stair bracket 50b is subjected to when compared to a stair bracket with a thicker tread measuring portion. In some instances, if the stair brackets 50a, 50b are positioned at maximum distances enabled by the stair brackets 50a, 50b from one another, the tread measuring portion 66 of the stair bracket 50a may intersect with the stair bracket 50a without there being an overlap.

[0085] Because of the very small thickness of the tread measuring portion 66 of the stair bracket 50a, the abutting surface 79 of the stair bracket 50b can be disposed above the tread measuring portion 66 of the stair bracket 50a. This enables the riser flange 64 to extend along all of the riser side 78, as the riser flange 64 does not need to define an opening for the tread measuring portion 66 of the stair bracket 50a, which reinforces the stair bracket 50. In some instances, this increased structural integrity provided by the riser flange 64 extending within the riser variation zone can enable the manufacture of thinner stair brackets 50, which can reduce manufacturing costs. In some instances, this increased structural integrity can enable the stair bracket to sustain vertical loads of up to about 2300 lbs (about 1040 kg), which can be significantly higher than loads that can be sustained by stair brackets in which the riser flange 64 does not extend along the riser variation zone. In some embodiments, the stair bracket according to the present technology can sustain up to 70% higher loads than some similarly sized stair brackets such as the ones disclosed in U.S. Patent No. 6,758,016 B2, issued on July 6, 2004.

[0086] Additionally, the increased structural integrity provided by the riser flange 64 extending along the entire riser side 78 enhances the resistance to lateral deformation of the stair brackets 50, thereby limiting lateral movement of the steps connected thereto. Indeed, when climbing stairs, steps may be subjected to lateral loads which can cause some lateral movement thereof. If this movement is not limited, the stairs may feel unstable.

[0087] By minimizing misalignment and therefore minimizing torsional loads that the stair bracket 50b is subjected to, life of the stair bracket 50 can be increased as it is subjected to less stress. Additionally, as a result of minimizing torsional loads, lateral loads or bending stresses on screws are reduced, which can reduce screw fatigue. Also, noises such as squeaks, which can result from engaging surfaces not being flush with one another, can also be reduced.

[0088] Fasteners connecting the stair bracket 50 to the supporting member 130 are also subjected to less stress. Additionally, noise that the stair bracket 50 may cause over time while in use (e.g., when someone steps on the stairs) can be reduced.

[0089] By using the tread measuring portion 66 of the stair bracket 50a and the riser measuring portion 68 of the stair bracket 50b, the stair bracket 50b can be precisely positioned for providing the desired riser height and desired tread depth. The disposition of the graduations can help in positioning the stair bracket 50b relative to the stair bracket 50a more precisely, as the graduations are easy to read being that they extend generally perpendicularly from the supporting member 130.

[0090] Then, the method continues with connecting the stair bracket 50b to the supporting member 130 by inserting two fasteners 140 through two riser apertures 87, and by inserting two other fasteners 140 in two tread apertures 83. The riser apertures 87 through which the other fasteners 140 are inserted may be selected to be spaced from one another to increase stability of the stair bracket 50b. It will be appreciated that according to the present technology, there is no need to align the riser apertures 87 of the stair bracket 50b with any part of the stair bracket 50a, such as another aperture. Additionally, if one of the riser apertures 87 is aligned with the tread measuring portion 66, due to the nature of the tread measuring portion 66 (flexible and thin), it can easily be pierced by a fastener. This canfacilitate connection of the stair bracket 50b to the supporting member 130, relative to the stair bracket 50a.

[0091] Additional brackets 50, as required, are connected to the supporting member 130 as described hereabove.

[0092] Then, depending on the desired riser height and a size of the riser side 78, it may be necessary to cut part of the stair bracket 50a and part of the supporting member 130. In some instances, the stair bracket 50a may be machined into its final shape. This can be done with readily available tools by using the graduations of the riser measuring portion 68 as a reference. It is understood that this step, of cutting the stair bracket 50a, may be performed once all the brackets 50 have been connected to the supporting member 130.

[0093] Then, the method continues by connecting a left base bracket 120 to the left supporting member 130 via fasteners 121 (Figure 10). The left base bracket 120 is partially complementary to the supporting member 130. Additionally, the left base bracket 120 is a commonly available bracket, and thus will not be described in detail herewith.

[0094] Right brackets 52a, 52b and a right base bracket 122 are connected to the right supporting member 132 following steps described hereabove.

[0095] Then, the method continues by connecting a riser 135a to the left and right brackets 50a, 52a via fasteners inserted through corresponding riser connecting apertures 65, and connecting a riser 135b to the left and right brackets 50b, 52b via fasteners inserted through corresponding riser connecting apertures 65. It will be appreciated that connection between the risers 135a, 135b to the brackets 50a, 52a, 50b, 52b is enhanced by the riser flange 64 extending along a bottom of the risers 135a, 135b (due to the riser flange 64 extending into the riser variation zone). Then, the tread 134a is connected to the left and right brackets 50a, 52a via fasteners inserted through corresponding tread connecting apertures 63. The tread 134a can be put flush against the risers 135a, 135b, which can facilitate connection thereof.

[0096] Referring to Figure 12B, in which alternative embodiments of the tread 134a’, 134b’ are shown, the tread 134a’ is connected to the left and right brackets 50a, 52a beforethe riser 135b’ is connected to the brackets 50b, 52b. In this embodiment, the treads 134a’, 134b’ have a tread overhang of 0.5” (1.27 cm). It will be appreciated that due to the tread measuring portions 66 only measuring one inch beyond the stair brackets 50a, 50b, the maximum tread overhang possible is limited.

[0097] Then, the supporting members 130, 132 can be moved to their mounting position, before repeating the above-described method with additional brackets 50, 52 and additional treads 134 and risers 135 until construction of the stairs is finished.

[0098] The order in which the method is described is exemplary and steps may be reordered in other embodiments. For example, in some embodiments, all of the left brackets 50 could be connected to the left supporting member 130, and all of the right brackets 52 could be connected to the right supporting member 132, before connecting any of the treads 134 and / or risers 135 to their respective brackets 50, 52 and / or before moving the supporting members 130, 132 to their mounting positions. In other embodiments, the base brackets 120, 122 and lowermost brackets 50, 52 could be connected to the supporting members 130, 132, the supporting members 130, 132 may be moved to their mounting positions, and then the other brackets 50, 52 could be connected to the supporting members 130, 132. In other embodiments, all of the left brackets 50 could be connected to the left supporting member 130, all of the right brackets 52 could be connected to the right supporting member 132, and all of the treads 134 and the risers 135 may be connected to their respective brackets 50, 52 before moving the supporting members 130, 132 to their mounting positions.

[0099] It is contemplated that the left and / or right brackets 50, 52 could be connected to a central supporting member, and then risers, treads and additional side supporting members, could be connected afterwards.

[0100] Modifications and improvements to the above-described embodiments of the present invention may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the present invention is therefore intended to be limited solely by the appended claims.

Claims

What is claimed is:

1. A stair bracket comprising: a body having a first body end, a second body end and a third body end, and the body defining: a tread side extending from the first body end to the second body end; and a riser side extending from the first body end to the third body end, the riser side being orthogonal to the tread side; a tread flange connected to the body at the tread side, the tread flange having a first tread flange end and a second tread flange end, and extending orthogonally away from the body, part of the tread flange extending along the tread side between the first tread flange end and the second tread flange end; a tread measuring portion disposed at the second body end, the tread measuring portion being graduated; a riser flange connected to the body at the riser side, the riser flange having a first riser flange end and a second riser flange end, and extending orthogonally away from the body, part of the riser flange extending along the riser side between the first riser flange end and the second riser flange end, and the second riser flange end being disposed within a riser variation zone provided by the stair bracket.

2. The stair bracket of claim 1, wherein at least one of: the first tread flange end is generally aligned with the first body end; and the second tread flange end is generally aligned with the second body end.

3. The stair bracket of claim 1 or 2, wherein at least one of:the first riser flange end is generally aligned with the first body end; and the second riser flange end is generally aligned with the third body end.

4. The stair bracket of any one of claims 1 to 3, wherein the tread flange and the riser flange extend orthogonally away from the body in a same direction.

5. The stair bracket of any one of claims 1 to 4, further comprising at least one of tread connecting apertures defined in the tread flange, and riser connecting apertures defined in the riser flange.

6. The stair bracket of any one of claims 1 to 5, wherein the tread measuring portion is connected to the body.

7. The stair bracket of claim 6, wherein the tread measuring portion is selectively connected to the body.

8. The stair bracket of claim 6 or 7, wherein the tread measuring portion is connected to the body via an adhesive.

9. The stair bracket of any one of claims 6 to 8, wherein the tread measuring portion has a free end, and the second body end is between the first body end and the free end.

10. The stair bracket of claim 9, wherein a distance between the second body end and the free end is less than or equal to one inch.

11. The stair bracket of claim 9 or 10, wherein the tread measuring portion is foldable between: an in-use configuration, in which the second body end is between the first body end and the free end of the tread measuring portion, and a storage configuration, in which the free end of the tread measuring portion is between the first body end and the second body end.

12. The stair bracket of any one of claims claim 9 to 11, wherein part of the tread measuring portion can fold about the second body end.

13. The stair bracket of any one of claims 1 to 12, wherein the tread measuring portion is flexible.

14. The stair bracket of any one of claims 1 to 13, wherein a thickness of the tread measuring portion is less than 1 mm.

15. The stair bracket of any one of claims 1 to 14, wherein: a tread edge is defined by the body and the tread flange, and ends of graduations of the tread measuring portion are aligned with the tread edge.

16. The stair bracket of any one of claims 1 to 15, further comprising a riser measuring portion disposed at the second riser flange end, the riser measuring portion being graduated.

17. The stair bracket of claim 16, wherein the riser measuring portion is connected to the riser flange.

18. The stair bracket of claim 17, wherein the riser measuring portion is selectively connected to the riser flange.

19. The stair bracket of claim 17 or 18, wherein the riser measuring portion is connected to the riser flange via an adhesive.

20. The stair bracket of any one of claims 16 to 19, wherein one end of the riser measuring portion is aligned with the third body end.

21. The stair bracket of any one of claims 16 to 20, wherein: a riser edge is defined by the body and the riser flange, and ends of graduations of the riser measuring portion are aligned with the riser edge.

22. The stair bracket of any one of claims 1 to 21, further comprising:a plurality of tread apertures defined on the body, the plurality of tread apertures being positioned between the first tread flange end and the second tread flange end; and a plurality of riser apertures defined on the body, the plurality of riser apertures being positioned between the first riser flange end and the second riser flange end.

23. The stair bracket of claim 22, wherein the body includes: a tread supporting portion and a tread connecting portion, the tread supporting portion and the tread connecting portion extending along and away from the tread side, the tread connecting portion extending further away from the tread side than the tread supporting portion, and the plurality of tread apertures being defined on the tread connecting portion; and a riser supporting portion and a riser connecting portion, the riser supporting portion and the riser connecting portion extending along and away from the riser side, the riser connecting portion extending further away from the riser side than the riser supporting portion, and the plurality of riser apertures being defined on the riser connecting portion.

24. The stair bracket of any one of claims 1 to 23, wherein the body generally defines an L-shape.

25. The stair bracket of any one of claims 1 to 24, wherein the body, the tread flange and the riser flange are unitary.

26. A method for connecting a plurality of stair brackets to a supporting member, the method comprising:connecting a first stair bracket of the plurality of stair brackets to the supporting member such that with the supporting member being in a mounting position, a tread flange of the first stair bracket is generally horizontal, and a riser flange of the first stair bracket is generally vertical; positioning, relative to the first stair bracket, a second stair bracket of the plurality of stair brackets on the supporting member, at least part of a riser flange of the second stair bracket extending over a tread measuring portion of the first stair bracket such that the tread measuring portion of the first stair bracket is laterally between the second stair bracket and the supporting member, and with the supporting member being in a mounting position, a tread flange of the second stair bracket is generally horizontal, and a riser flange of the second stair bracket is generally vertical; and connecting the second stair bracket to the supporting member.

27. The method of claim 26, wherein with the supporting member being in a mounting position, the second stair bracket is positioned vertically higher than the first stair bracket.

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