Modular stair system
Patent Information
- Application Number
- PCT/US2026/016153
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-02-22
- Filing Date
- 2026-02-22
- Publication Date
- 2026-08-27
Smart Images

Figure US2026016153_27082026_PF_FP_ABST
Abstract
Description
727644.00845MODULAR STAIR SYSTEMRELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No.63 / 761,972 filed February 22, 2025, the content of which is incorporated by this reference in its entirety for all purposes as if fully set forth herein.TECHNICAL FIELD
[0002] The present disclosure relates generally to the field of raised deck, stair, and flooring systems.BACKGROUND
[0003] Conventional stair systems tend to lack certain features that facilitate ease of assembly, transportation, configurability, and manufacturability.SUMMARY
[0004] Certain deficiencies of the prior art may be overcome by the provision of a modular stair system including a stair module and a stair module co-packaging assembly, certain non-limiting implementations of which are disclosed herein.BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Further advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description of the preferred embodiments and upon reference to the accompanying drawings in which:727644.00845
[0006] FIG. 1 is a diagrammatic perspective view of one example modular stair system;
[0007] FIG. 2 is a diagrammatic partially-exploded view of the modular stair system of FIG. 1, wherein an example side trim panel and two example front trim panels are separated to expose a variety of underlying aspects;
[0008] FIG. 3 is a diagrammatic perspective view similar to that of FIG. 2, but wherein the side trim panel and front trim panels are removed, illustrating a first stair module, a second stair module, and a third stair module in respective mutual modular engagements;
[0009] FIG. 4 is a diagrammatic perspective view of one example stair module;
[0010] FIG. 5 is a second diagrammatic perspective view of the stair module of FIG. 4;
[0011] FIG. 6 is a third diagrammatic perspective view of the stair module of FIG. 4;
[0012] FIG. 7 is a diagrammatic bottom view of the stair module of FIG. 4;
[0013] FIG. 8 is a diagrammatic front view of the stair module of FIG. 4;
[0014] FIG. 9 is a diagrammatic rear view of the stair module of FIG. 4;
[0015] FIG. 10 is a diagrammatic top view of the stair module of FIG. 4;
[0016] FIG. 11 is a diagrammatic side view of the stair module of FIG. 4;727644.00845
[0017] FIG. 12 is a diagrammatic cross-section view taken along lines 12-12 in FIG. 10, illustrating a variety of aspects including an example forward fastener access relief and an example spacer mount aperture;
[0018] FIG. 13 is a diagrammatic cross-section view taken along lines 13-13 in FIG. 10, illustrating a variety of aspects including example upper and lower arrays of alternating teeth and grooves;
[0019] FIG. 14 is a diagrammatic cross-section view similar to that of FIG. 13, but wherein an example lower adjacent stair module is shown with its upper array of alternating teeth and grooves in intermeshing engagement with the lower array of alternating teeth and grooves of the stair module;
[0020] FIG. 15 is a diagrammatic cross-sectional view similar to that of FIG. 14, but wherein an example longitudinal offset distance has been increased;
[0021] FIG. 16 is a diagrammatic perspective view of a pair of example stair modules in a precursor configuration prior to being placed in coupled engagement;
[0022] FIG. 17 is a diagrammatic perspective view similar to that of FIG. 16, but wherein the stair modules are in coupled engagement;
[0023] FIG. 18 is a diagrammatic partial magnified view of the configuration of FIG. 16;
[0024] FIG. 19 is a diagrammatic partial magnified view of the configuration of FIG. 17, but wherein a plurality of example coupler elements are shown in a precursor configuration prior to being removably secured;727644.00845
[0025] FIG. 20 is a diagrammatic partial magnified view similar to that of FIG.19, but wherein example coupler pins are shown extending through respective axially aligned pairs of coupler apertures;
[0026] FIG. 21 is a diagrammatic partial magnified view similar to that of FIG.20, but wherein example coupler clips are shown removably secured to the coupler pins;
[0027] FIG. 22 is a diagrammatic perspective of a pair of example stair modules in a precursor configuration prior to being placed in co-packaged engagement and illustrating a variety of co-packaging relief slots disposed in the tray support lips;
[0028] FIG. 23 is a diagrammatic perspective view similar to that of FIG. 22, but wherein the stair modules are shown in co-packaged engagement;
[0029] FIG. 24 is a diagrammatic side view of the configuration of FIG. 22;
[0030] FIG. 25 is a diagrammatic side view of the co-packaged engagement configuration of FIG. 23;
[0031] FIG. 25A is a diagrammatic side view of a stack of co-packaged stair modules;
[0032] FIG. 26 is a diagrammatic front view of the co-packaged engagement configuration of FIG. 23;
[0033] FIG. 27 is a diagrammatic top view of the co-packaged engagement configuration of FIG. 23;
[0034] FIG. 28 is a diagrammatic perspective view of the modular stair system of FIG. 1, but wherein two example floor panels are removed to expose two example upper panels of respective stair modules;727644.00845
[0035] FIG. 29 is a diagrammatic perspective view similar to that of FIG. 28, but wherein a plurality of example floor panels are separated from the system to expose a plurality of example upper panels and example flooring support trays;
[0036] FIG. 30 is a diagrammatic perspective view similar to that of FIG. 28, but wherein a plurality of trim panels and a flooring support tray have been removed to expose underlying aspects;
[0037] FIG. 31 is a second diagrammatic perspective view of the modular stair system of FIG. 1;
[0038] FIG. 32 is a diagrammatic side view of the modular stair system of FIG. 1;
[0039] FIG. 33 is a second diagrammatic side view of the modular stair system of FIG. 1;
[0040] FIG. 34 is a diagrammatic bottom view of the modular stair system of FIG. 1;
[0041] FIG. 35 is a diagrammatic rearview of the modular stair system of FIG. 1;
[0042] FIG. 36 is a diagrammatic top view of the modular stair system of FIG. 1 ;
[0043] FIG. 37 is a diagrammatic cross-sectional view taken along lines 37-37 in FIG. 36;
[0044] FIG. 38 is a diagrammatic cross-sectional view taken along lines 38-38 in FIG. 36;
[0045] FIG. 39 is a diagrammatic cross-sectional view taken along lines 39-39 in FIG. 36;727644.00845
[0046] FIG. 40 is a diagrammatic cross-sectional view taken along lines 40-40 in FIG. 36;
[0047] FIG. 41 is a diagrammatic cross-sectional view taken along lines 41-41 in FIG. 36;
[0048] FIG. 42A is a diagrammatic magnified view of detail 42A in FIG. 2;
[0049] FIG. 42B is a diagrammatic magnified view similar to that of FIG. 42A, but wherein the stair modules are shown secured to one another by way of an example forward fastener extending through a forward fastener aperture;
[0050] FIG. 43 is a diagrammatic magnified view of detail 43 in FIG. 31; showing an example tray supporting engagement;
[0051] FIG. 44A is a diagrammatic magnified view similar to that of detail 44B in FIG. 28, but wherein the example flooring securement block is shown separated from a corresponding securement block chamber;
[0052] FIG. 44B is a diagrammatic magnified view of detail 44B in FIG. 28, wherein the securement block chamber is in receipt of the flooring securement block;
[0053] FIG. 44C is a diagrammatic magnified view similar to that of FIG. 44B, but wherein the upper panel is in floor supporting engagement with an example floor panel and a plurality of flooring securement fasteners are shown in threaded engagement with the flooring securement block and the upper panel of a respective stair module;
[0054] FIG. 45A is a diagrammatic magnified view of detail 45A in FIG. 30, wherein a plurality of forward and lateral bracket mount apertures and a plurality of forward and lateral hanger mount apertures mountingly engage respective trim hangers and retention brackets;727644.00845
[0055] FIG. 45B is a diagrammatic magnified view similar to that of FIG. 45A, but wherein an example front trim panel is in forward affixed engagement with the front panel by way of hanging receipt and forward restraint, and an example lateral trim panel is in lateral affixed engagement with the lateral panel by way of hanging receipt and lateral restraint;
[0056] FIG. 46 is a diagrammatic magnified side view similar to that of FIG. 45B, but from a side viewing angle;
[0057] FIG. 47A is a diagrammatic magnified view of detail 47A in FIG. 3, wherein a plurality of forward and lateral retention brackets and a plurality of stair lights are shown in a precursor configuration prior to being mountingly received;
[0058] FIG. 47B is a diagrammatic magnified view similar to that of FIG. 47A, but wherein the forward and lateral retention brackets and the plurality of stair lights are shown mountingly received by the stair modules, and a front trim panel and a lateral trim panel are shown in affixed engagement;
[0059] FIG. 48 is a diagrammatic magnified view of detail 48 in FIG. 37, illustrating a cross-sectional view of an example forward retention bracket in restraint of an example front trim panel;
[0060] FIG. 49A is a diagrammatic magnified view similar to that of detail 49B in FIG. 30, but wherein an example mountable flooring spacer is shown in a precursor configuration prior to being mountingly retained by a corresponding example spacer mount aperture;
[0061] FIG. 49B is a diagrammatic magnified view of detail 49B in FIG. 30, wherein the example spacer mount aperture mountingly retains the example mountable flooring spacer;727644.00845
[0062] FIG. 49C is a diagrammatic magnified view similar to that of FIG. 49B, but wherein the mountable flooring spacer is in mounted spacing communication between an example coplanar arranged pair of floor panels;
[0063] FIG. 50A is a diagrammatic magnified view of detail 50A in FIG. 40, wherein an example fastenable spacer is placed in a precursor configuration prior to being placed in fastened engagement with an upper panel of a stair module and prior to being placed in fastened spacing communication between a coplanar arranged pair of floor panels;
[0064] FIG. 50B is a diagrammatic magnified view similar to that of FIG. 50A, but wherein an example spacer fastener places the fastenable spacer in fastened engagement with the upper panel of the stair module and in fastened spacing communication between the coplanar arranged pair of floor panels;
[0065] FIG. 51 is a diagrammatic magnified view of detail 51 in FIG. 38, wherein an example pedestal is in stair supporting engagement of an example stair module, an example pedestal engagement portion being secured to an example stair support element;
[0066] FIG. 52 is a diagrammatic magnified view of detail 52 in FIG. 38, wherein an example fascia clip is engaged to an example auxiliary pedestal flange, an example horizontal frame member is engaged to the fascia clip, and an example frame member trim hanger is mounted to the horizontal frame member in hanging receipt of a trim panel;
[0067] FIG. 53 is a diagrammatic cross-section view similar to that of FIG. 15, but wherein a plurality of joists are shown in stair supporting engagement with corresponding support sections of respective stair modules;
[0068] FIG. 54 is a diagrammatic side view of an example coupler pin;727644.00845
[0069] FIG. 55 is a diagrammatic perspective view of an example coupler element in a precursor configuration prior to a coupler clip being secured to the coupler pin of FIG. 54;
[0070] FIG. 56 is a diagrammatic perspective view similar to that of FIG. 55, but wherein the coupler clip is secured to the coupler pin;
[0071] FIG. 57 is a further diagrammatic perspective view of the example coupler element shown in FIG. 56;
[0072] FIG. 58 is a diagrammatic perspective view of an example retention bracket;
[0073] FIG. 59 is a diagrammatic perspective view of an example trim hanger;
[0074] FIG. 60 is a diagrammatic perspective view of an example frame member trim hanger;
[0075] FIG. 61 is a diagrammatic perspective view of an example fastenable spacer;
[0076] FIG. 62 is a second diagrammatic perspective view of the fastenable spacer of FIG. 61;
[0077] FIG. 63 is a diagrammatic perspective view of an example mountable flooring spacer;
[0078] FIG. 64 is a second diagrammatic perspective view of the mountable flooring spacer of FIG. 63;
[0079] FIG. 65 is a diagrammatic perspective view of an example pedestal;727644.00845
[0080] FIG. 66 is a diagrammatic front view of the pedestal of FIG. 65;
[0081] FIG. 67 is a diagrammatic cross-sectional view taking along lines 67-67 in FIG. 66;
[0082] FIG. 68 is a diagrammatic exploded view of the pedestal of FIG. 65;
[0083] FIG. 69 is a second diagrammatic exploded view of the pedestal of FIG.65;
[0084] FIG. 70 is a diagrammatic perspective view of a fascia clip and an auxiliary pedestal flange in a precursor configuration prior to a slot of a pedestal interface portion being in engaged receipt of the auxiliary pedestal flange;
[0085] FIG. 71 is a diagrammatic perspective view similar to that of FIG. 70, but wherein the slot is in engaged receipt of the auxiliary pedestal flange, and an example fascia fastener element is in a precursor configuration prior to extending through the corresponding apertures;
[0086] FIG. 72 is a diagrammatic perspective view similar to that of FIG. 71, but wherein an example pair of fastener pins of the fascia fastener element extend through the respective example pin alignment apertures and the respective example attachment apertures;
[0087] FIG. 73 is a diagrammatic perspective view similar to FIG. 72, but from a different viewing angle;
[0088] FIG. 74 is a diagrammatic side view of FIG. 72; and
[0089] FIG. 75 is a diagrammatic cross-sectional view taken along lines 75-75 in FIG. 74.727644.00845DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0090] Referring now to the drawings, like reference numerals designate identical or corresponding features throughout the several views.
[0091] With reference to several of the drawings, a modular stair system is shown generally at 100, a stair module is shown generally at 102, and a stair module copackaging assembly is shown generally at 103.
[0092] Anywhere a letter is used in conjunction with a reference number in the present specification and drawings, it is intended to identify a specific instance of the general case. For example, the stair module is shown generally at 102 and specific instances of the stair module 102 may be denoted at 102a-102h. In certain implementations of the stair module 102, each of these instances may be structurally identical to one another while in other implementations the feature sets may differ from one another.
[0093] In the present specification, unless the particular nature of a fastener is described or claimed, the term fastener may be used to denote fastening by way of adhesion, a rivet, a bolt, a screw, a nail, a nut, some combination thereof, or the like.
[0094] Referring to FIG. 4, a stair module 102 may comprise a forward end 117 and a rearward end 119 disposed oppositely of one another. An upper panel 122 may span between the forward end 117 and the rearward end 119. A longitudinal axis 118 may be defined as extending parallel to the upper panel 122 from the rearward end 119 through the forward end 117. A vertical axis 116 may be defined perpendicularly to the upper panel 122. The upper panel 122 may include one or more upper longitudinal alignment tracks 182.
[0095] Referring to FIG. 5, a lower portion 124 may be disposed oppositely of the upper panel 122. The lower portion 124 may include one or more lower longitudinal727644.00845alignment tracks 184.
[0096] Referring to FIGS. 14 and 15, certain implementations of the stair module 102 may be placed in mutual modular engagement with a lower adjacent stair module 102f. In the mutual modular engagement, a longitudinal offset distance 134 may be defined between the forward end 117 of the stair module 102 and the forward end 117 of the lower adjacent stair module 102f. In the mutual modular engagement, the one or more lower longitudinal alignment tracks 184 of the stair module 102 may be in mutual track engagement with respective upper longitudinal alignment tracks 182 of the lower adjacent stair module 102f. The mutual track engagement may be selectably positionable to adjust the longitudinal offset distance 134. The mutual track engagement may restrict linear movement between the stair module 102 and the lower adjacent stair module 102f along the longitudinal axis 118 of the stair module 102. The mutual track engagement may restrict rotational movement between the stair module 102 and the lower adjacent stair module 102f about the vertical axis 116 of the stair module. Additional stair modules 102 may be connected in mutual modular engagement in a similar fashion, in an upward direction 113 and a downward direction 115, alternatively or in addition.
[0097] Referring to FIGS. 13-15, the one or more lower longitudinal alignment tracks 184 may each comprise a lower array of alternating teeth and grooves 185. The one or more upper longitudinal alignment tracks 182 may each comprise an upper array of alternating teeth and grooves 183. In such implementations of the stair module 102, mutual modular engagement between stair modules 102 may be by way of the lower array 185 of a lower longitudinal alignment track 184 of a stair module 102 being placed in intermeshing engagement with the upper array 183 of an upper longitudinal alignment track 182 of a lower adjacent stair module 102f.
[0098] Referring to FIGS. 4 and 29, the upper panel 122 may be in floor supporting engagement with a floor panel 108. The floor panel may be, for example, a tile, paver, paving stone, horizontal slat, some combination thereof, or the like. A plurality of upper adhesive apertures 188 may extend through the upper panel 122. In727644.00845such implementations of the stair module 102, the floor supporting engagement may be securable at least by way of adhesive bonding between the floor panel 108 and the upper adhesive apertures 188. In some such implementations of the stair module 102, a multiplicity of adhesive ribs 189 may extend beneath respective sets of the upper adhesive apertures 188 (see, for example, FIG. 5).
[0099] In particular implementations of the stair module 102, the floor supporting engagement may be securable at least by way of one or more flooring securement fasteners 234 in threaded engagement with the upper panel 122 (see, for example, FIG.44C). Referring to FIGS 4, 5, and 13, in some such particular implementations of the stair module 102, one or more securement block chambers 200 may be disposed between the upper panel 122 and a corresponding lower longitudinal alignment track 184. In some cases, the securement block chamber 200 may be defined within a track boss 201. The securement block chamber 200 may have a chamber mouth 199 at the upper panel 122. The securement block chamber 200 may receive a flooring securement block 232 by way of the chamber mouth 199 (see, for example, FIG. 44 A). The securement block chamber 200 may retain a flooring securement block 232 therein (see, for example, FIG 44B). In such implementations of the stair module 102, the floor supporting engagement may be securable at least by way of the one or more flooring securement fasteners 234 being in threaded engagement with one or more said flooring securement blocks 232 (see, for example, FIG. 44C).
[0100] Referring to FIGS. 4 and 12, the upper panel 122 may include one or more spacer mount apertures 198. Each spacer mount aperture 198 may mountingly retain a flooring spacer (see, for example, FIGS. 49A and 49B).
[0101] Referring to FIGS. 5-7, certain implementations of the stair module 102 may include a plurality of pedestal engagement portions 202. The pedestal engagement portions 202 may be disposed on an upper inboard surface 148 of the upper panel 122. The pedestal engagement portions 202 may have one or more pedestal securement clips 206, for example, a cantilever snap, to releasably secure an upper annular flange 264 of a727644.00845pedestal 110 to the pedestal engagement portion 202 (see, for example, FIG. 51). The pedestal engagement portions 202 may include a pedestal alignment lip 204 to aligningly receive the upper annular flange 264 of the pedestal 110.
[0102] Referring to FIG. 4, particular implementations of the stair module 102 may comprise one or more stair light reliefs 194. The stair light reliefs 194 may be disposed along an upper forward edge 138 of the upper panel 122. The stair light reliefs 194 may receivably engage a relief engagement portion 229 of a stair light 228 (see, for example, FIGS. 47A and 47B). In such engagement, the lighting portion 230 of the stair light 228 may overhang the respective front trim panel 133 (see, for example, FIG. 48).
[0103] Referring to FIGS. 5 and 6, certain implementations of the stair module 102 may comprise a rib substructure 207 disposed between the upper panel 122 and the lower portion 124. The rib substructure 207 may provide additional structural integrity to the stair module 102. The rib substructure 207 may also include a plurality of coupler storage apertures 187 to, for example, store a plurality of coupler elements 218 therein. The stair module 102 may include a lateral axis 120 being defined perpendicularly to the longitudinal axis 118 and the vertical axis 116 (see, for example, FIG. 4). A pair of lateral ends 121 may be disposed oppositely of one another along the lateral axis 120. The rib substructure 207 may include one or more longitudinal ribs 208 extending longitudinally between the forward end 117 and the rearward end 119. The rib substructure 207 may include one or more spar ribs 210 extending laterally between the lateral ends 121. In some implementations of the stair module 102, the spar ribs 210 may span between a pair of lateral panels 130 at the lateral ends 121 (see, for example, FIG. 4). One or more lateral ribs 212 may intersect at least a set of the longitudinal ribs 208 to, for example, provide additional structural rigidity.
[0104] Referring to FIG. 4, some implementations of the stair module 102 may comprise a front panel 126 extending from the upper panel 122 to the lower portion 124 at the forward end 117.727644.00845
[0105] A plurality of forward hanger mount apertures 171 may extend through the front panel 126. The forward hanger mount apertures 171 may each mountingly receive a front trim hanger 290a (see, for example, FIG. 45A). In some such implementations of the stair module 102, at least a subset of the forward hanger mount apertures 171 may be arranged in one or more laterally-distributed rows. The laterally-distributed rows may be vertically offset from one another.
[0106] A plurality of forward bracket mount apertures 174 may extend through the upper panel 122 along its upper forward edge 138. The forward bracket mount apertures 174 may each mountingly receive a forward retention bracket 224a (see, for example, FIGS 45A and 47A).
[0107] A plurality of forward adhesive apertures 190 may extend through the front panel 126. The forward adhesive apertures 190 may facilitate an adhesive bond between the front panel 126 and a front trim panel 133 (see, for example, FIG. 2). The front trim panel 133 may be, for example, a vertical tile, a vertical slat, some combination thereof, or the like.
[0108] Some implementations of the stair module 102 may include one or more forward fastener access reliefs 178. The forward fastener access reliefs 178 may be disposed between the upper panel 122 and the lower portion 124 at the forward end 117. The forward fastener access reliefs 178 may include an access relief floor 179 extending from a lower forward edge 140 of the front panel 126. The forward fastener access reliefs 178 may allow access to respective forward fastener apertures 180 disposed on the access relief floors 179. Such implementations of the stair module 102 may be secured to the lower adjacent stair module 102f by way of one or more forward fasteners 181 extending through the forward fastener apertures 180 (FIGS. 42A and 42B). In this secured configuration, the respective longitudinal offset distance 134 may be positionally locked (see, for example, FIG. 14).
[0109] Certain implementations of the stair module 102 may comprise a pair of727644.00845lateral panels 130 disposed oppositely of one another along a lateral axis 120. The lateral axis 120 may be defined orthogonally to the longitudinal axis 118 and to the vertical axis 116.
[0110] A plurality of lateral hanger mount apertures 170 may extend through each lateral panel 130. The lateral hanger mount apertures 170 may each mountingly receive a lateral trim hanger 290b (see, for example, FIG. 45A). In some such implementations of the stair module 102, at least a subset of the lateral hanger mount apertures 170 may be arranged in one or more longitudinally-distributed rows. The longitudinally-distributed rows may be vertically offset from one another.[OHl] A plurality of lateral bracket mount apertures 176 may extend through the upper panel 122 along the upper lateral edges 145 of the lateral panels 130. The lateral bracket mount apertures 176 may each mountingly receive a lateral retention bracket 224b (see, for example, FIGS. 45A and 47A).
[0112] A plurality of lateral adhesive apertures 192 may extend through the lateral panels 130. The lateral adhesive apertures 192 may facilitate an adhesive bond between the lateral panels 130 and the lateral trim panels 131 (see, for example, FIG. 2). The lateral trim panels 131 may be, for example, a vertical tile or vertical slat, some combination thereof, or the like.
[0113] Referring to FIGS. 4-6 and 16-21, in particular implementations of the stair module 102, one or more coupler apertures 186 may extend through each of the lateral panels 130. The coupler apertures 186 may each have a coupler element 218 extending therethrough. Such implementations of the stair module 102 may be placed in coupled engagement with a co-lateral stair module 102g. In the coupled engagement, a right lateral panel 130a of the co-lateral stair module 102g may be positioned laterally adjacent of a left lateral panel 130b of the stair module 102. In the coupled engagement, one or more axially aligned pairs of the coupler apertures 186 may have a coupler element 218 extending therethrough, the one or more axially aligned pairs being defined727644.00845as the one or more coupler apertures 186 of the right lateral panel 130a of the co-lateral stair module 102g in axial alignment with the one or more coupler apertures 186 of the left lateral panel 130b of the stair module 102. Referring to FIG. 5 and 9, in some implementations of the stair module 102, the rib substructure 207 may include a plurality of coupler storage apertures 187. The coupler storage apertures 187 may, for example, be used to store coupler elements 218 when not in use.
[0114] One or more coupler access channels 196 may be disposed laterally inboard of each lateral panel 130. The coupler access channels 196 may be in communication with one or more of the coupler apertures 186. The coupler access channels 196 may include an access channel upper mouth 197 at the upper panel 122. The coupler access channels 196 may include an access channel lower mouth 195 at the lower portion 124.
[0115] Referring to FIGS. 5-7, in certain implementations of the stair module 102, a rear panel 128 may extend from the upper panel 122 toward the lower portion 124 at the rearward end 119. A tray support lip 168 may extend from the rear panel 128. The tray support lip 168 may engage a flooring support tray at the rearward end (see, for example, FIG. 43). The tray support lip 168 may be disposed at a rearward support distance 161 from the upper panel 122 (see, for example, FIG. 11).
[0116] Referring to FIGS. 22-27, particular implementations of the stair module 102 may be placed in co-packaged engagement with a co-packaged stair module 102h. In such implementations of the stair module 102, the tray support lip 168 may include a plurality of co-packaging relief slots 270. In the co-packaged engagement, the tray support lip 168 of the stair module 102 may be received by the lower portion 124 of the co-packaged stair module 102h, and the lower portion of the stair module 102 may receive the tray support lip 168 of the co-packaged stair module 102h. In some such implementations of the stair module 102, a first set of the co-packaging relief slots 270 may have a rib receiving width 272 to receivably engage a longitudinal rib 208 of the copackaged stair module 102h. A second set of the co-packaging relief slots 270 may have727644.00845a track boss receiving width 274 to receivably engage a track boss 201 of the copackaged stair module 102h, wherein, as shown in FIG. 5, the stair module 102 may have one or more track bosses 201 each extending from the upper panel 122 to a respective lower longitudinal alignment track 184 (see, for example, FIG. 5).
[0117] Referring to FIG. 11, in certain implementations of the stair module 102, the lower portion 124 may include a forward support section 158, a rearward support section 160, and an intermediate support section 162 therebetween. The forward support section 158 may be disposed at a forward support distance 166 from the upper panel 122. The rearward support section 160 may be disposed at a rearward support distance 161 from the upper panel 122. The intermediate support section 162 may be disposed at an intermediate support distance 163 from the upper panel 122. The intermediate support distance 163 may be less than the forward support distance 166 and greater than the rearward support distance 161. In some such implementations of the stair module 102, the forward support section 158, the rearward support section 160, and the intermediate support section 162 may each be parallel to the upper panel 122, wherein, as shown in FIG. 53, each may supportedly engage a joist 111, for example, a 2x4 (see, for example, FIG. 53). The lower portion may also include a transitional section 164 disposed between the rearward support section 160 and the intermediate support section 162. The transitional section 164 may be oriented at an acute angle 165 with respect to the upper panel 122. The transitional section 164 may facilitate a greater surface area of contact between the lower portions 124 of co-packaged stair modules 102.
[0118] Particular implementations of the modular stair system 100 may comprise a plurality of stair modules 102. The stair modules 102 of the modular stair system 100 may include all or some combination of the features of the stair modules 102 as described previously herein. Referring to FIG. 3, the plurality of stair modules 102 may include a first stair module 102a and a second stair module 102b. The first stair module 102a may be placed in mutual modular engagement with the second stair module 102b positioned thereunder. In some implementations of the modular stair system 100, the plurality of stair modules 102 may include a third stair module 102c. The second stair module 102b727644.00845may be placed in mutual modular engagement with the third stair module 102c positioned thereunder.
[0119] Referring to FIG. 31, certain implementations of the modular stair system 100 may include one or more flooring support trays 106. In such implementations of the modular stair system 100, the first stair module 102a may be placed in tray supporting engagement with the flooring support tray 106 by way of its tray support lip 168 (see, for example, FIG. 43).
[0120] Referring to FIGS. 2 and 4, some implementations of the modular stair system 100 may include one or more floor panels 108. The upper panels 122 may be placed in floor supporting engagement with the floor panels 108. In certain implementations of the modular stair system 100, the floor supporting engagement may be securable at least by way of adhesive bonding between the floor panels 108 and the upper adhesive apertures 188. Referring to FIGS. 44A-44C, some implementations of the modular stair system 100 may comprise a plurality of flooring securement fasteners 234. The floor supporting engagement may be securable at least by way of a first set of the flooring securement fasteners 234 being in threaded engagement with the upper panel 122. The modular stair system 100 may further comprise a plurality of flooring securement blocks 232. In such implementations of the modular stair system 100, the floor supporting engagement may be securable at least by way of a second set of the flooring securement fasteners 234 being in threaded engagement with the flooring securement blocks 232 retained in the securement block chambers 200.
[0121] Referring to FIGS. 49A-49C and 63-64, particular implementations of the modular stair system 100 may comprise a plurality of mountable flooring spacers 280. The mountable flooring spacers 280 may be mountably retained by the spacer mount apertures 198. The mountable flooring spacers 280 may be placed in mounted spacing communication between a coplanar arranged pair of floor panels 108.
[0122] Referring to FIGS. 2 and 4, certain implementations of the modular stair727644.00845system 100 may include a plurality of front trim panels 133. The front trim panels 133 may be disposed in forward affixed engagement with the front panels 126. In some implementations of the modular stair system 100, the forward affixed engagement may be at least in part by way of adhesive bonding between the front trim panels 133 and the forward adhesive apertures 190. Referring to FIGS. 45A-46, particular implementations of the modular stair system 100 may include a plurality of front trim hangers 290a. In such implementations of the modular stair system 100, the forward hanger mount apertures 171 may each mountingly receive a front trim hanger 290a, wherein the forward affixed engagement may be at least in part by way of a subset of the front trim hangers 290a in hanging receipt of the front trim panels 133. In some such implementations of the modular stair system 100, the laterally-distributed rows of forward hanger mount apertures 171 may facilitate selectable vertical positioning of the front trim panels 133 relative to the front panels 126. Referring to FIGS. 47A-48, certain implementations of the modular stair system 100 may comprise a plurality of forward retention brackets 224a. In such implementations of the modular stair system 100, the forward bracket mount apertures 174 may each mountingly receive a forward retention bracket 224a, wherein the forward affixed engagement may be at least in part by way of a subset of the forward retention brackets 224a in forward restraint of the front trim panels 133.
[0123] Referring to FIGS. 42A and 42B, the modular stair system 100 may include a plurality of forward fasteners 181. In such implementations of the modular stair system 100, the stair modules 102 in mutual modular engagement may be secured to one another by way of one or more forward fasteners 181 extending through the forward fastener apertures 180.
[0124] Referring to FIGS. 2 and 4, certain implementations of the modular stair system 100 may include a plurality of lateral trim panels 131. The lateral trim panels 131 may be disposed in lateral affixed engagement with the lateral panels 130. In some implementations of the modular stair system 100, the lateral affixed engagement may be at least in part by way of adhesive bonding between the lateral trim panels 131 and the727644.00845lateral adhesive apertures 192. Referring to FIGS. 45A-46, particular implementations of the modular stair system 100 may include a plurality of lateral trim hangers 290b. In such implementations of the modular stair system, the lateral hanger mount apertures 170 may each mountingly receive a lateral trim hanger 290b, wherein the lateral affixed engagement may be at least in part by way of a subset of the lateral trim hangers 290b in hanging receipt of the lateral trim panels 131. In some such implementations of the modular stair system 100, the longitudinally -distributed rows of lateral hanger mount apertures 170 may facilitate selectable vertical positioning of the lateral trim panels 131 relative to the lateral panels 130. Referring to FIGS. 47A-48, certain implementations of the modular stair system 100 may comprise a plurality of lateral retention brackets 224b. In such implementations of the modular stair system 100, the lateral bracket mount apertures 176 may each mountingly receive a lateral retention bracket 224b, wherein the lateral affixed engagement may be at least in part by way of a subset of the lateral retention brackets 224b in lateral restraint of the lateral trim panels 131.
[0125] Referring to FIGS. 5OA-5OB and 61-62, the modular stair system 100 may include a plurality of fastenable spacers 282. The fastenable spacers 282 may each be placed in fastened engagement with a stair module 102 at the upper panel 122, the front panel 126, or one of the lateral panels 130. In the fastened engagement, the fastenable spacer 282 may be in fastened spacing communication between a corresponding pair of coplanar arranged floor panels 108, a corresponding pair of coplanar arranged front trim panels 133, or a corresponding pair of coplanar arranged lateral trim panels 131. In some such implementations of the modular stair system 100, each of the fastenable spacers 282 may include a panel insertion portion 283. A set of the floor panels 108, a set of the front trim panels 133, and a set of the lateral trim panels 131, may each include a spacer receiving edge groove 109. In such implementations of the modular stair system 100, in the fastened spacing communication, the panel insertion portions 283 may be inserted into corresponding spacer receiving edge grooves 109.
[0126] Referring to FIGS. 54-57, the modular stair system 100 may include a plurality of coupler elements 218. Each coupler element 218 may include a coupler pin727644.00845220 and a coupler clip 222. In some implementations of the modular stair system 100, the plurality of stair modules 102 may include a first co-lateral stair module 102d. The first co-lateral stair module 102d may be placed in a first coupled engagement, for example, as in FIGS. 16-21, with the first stair module 102a. In particular implementations of the modular stair system, the plurality of stair modules 102 may include a second co-lateral stair module 102e. The second co-lateral stair module 102e may be placed in a second coupled engagement, for example, as in FIGS. 16-21, with the second stair module 102b. In such implementations of the modular stair system 100, the first co-lateral stair module 102d and the second co-lateral stair module 102e may be in mutual modular engagement, for example, as in FIGS. 14-15, with one another.
[0127] Referring to FIG. 1, certain implementations of the modular stair system 100 may comprise a stair support substructure 104. The stair support substructure 104 may be in stair supporting engagement with the stair modules 102. Referring to FIGS. 2 and 38, in some implementations of the modular stair system 100, the stair support substructure 104 may comprise a plurality of pedestals 110. Referring to FIGS. 65-69, each pedestal 110 may have a base element 260, a stair support element 262 with an upper annular flange 264, and a pedestal tube 266 extending therebetween along a pedestal axis 268. In such implementations of the modular stair system 100, the stair modules 102 may be in the stair supporting engagement by way of one or more of their respective pedestal engagement portions 202 each being secured to a stair support element 262. In such, the corresponding pedestal securement clips 206 may retain the respective upper annular flange 264 in the respective pedestal alignment lip 204 (FIG.51). Alternatively or in addition, the pedestals 110 may be height-adjustable or come in different sizes to reach a variety of pedestal engagement portions 202 of the modular stair system 100.
[0128] Referring to FIGS 70-75, particular implementations of the modular stair system 100 may include a plurality of fascia clips 214. Each of the fascia clips 214 may have a pedestal interface portion 300 and frame member interface portion 308. One or more of the pedestals 110 may each include an auxiliary pedestal flange 267 through727644.00845which a plurality of attachment apertures 269 may extend. Each of the pedestal interface portions 300 may include a slot 302 to engageably receive an auxiliary pedestal flange 267. At least one pin alignment aperture 304 may intersect the slot 302. A corresponding fascia fastener element 306 may be manually installed in and removed from the pedestal interface portion 300. Each said fascia fastener element 306 may include at least one fastener pin 307 to extend through a respective pin alignment aperture 304 and a respective attachment aperture 269 when the fascia fastener element 306 is installed. Some such particular implementations of the modular stair system 100 may include a plurality of horizontal frame members 216. The frame member interface portions 308 may each receivably engage a horizontal frame member 216 (FIG. 52). Referring to FIGS. 52 and 60, a plurality of frame member trim hangers 330 may be mountably secured to the horizontal frame members 216, wherein the frame member trim hangers 330 may each be in hanging receipt of a lateral trim panel 131.
[0129] Referring to FIG. 53 in certain implementations of the modular stair system 100, the stair support substructure 104 may include a plurality of joists 111. The joists 111 may be used alternatively or in addition to the pedestals 110. Each of the joists 111 may be in joist supporting engagement with a forward support section 158, an intermediate support section 162, or a rearward support section 160, of the stair modules 102. In some implementations of the modular stair system 100, the joists 111 may be laterally extending to, for example, provide vertical and lateral structural support to the modular stair system 100, while a plurality of horizontal frame members 216 may be affixed to the fascia clips 214 to, for example, provide longitudinal structural support to the modular stair system 100. In some such implementations of the modular stair system 100, the horizontal frame members 216 and the joists 111 may comprise, for example, 2x4 wood members.
[0130] Referring to FIGS. 47A-48, the modular stair system 100 may include a plurality of stair lights 228. The stair lights 228 may each have a relief engagement portion 229 and a lighting portion 230. The relief engagement portion 229 may be insertably received by a stair light relief 194. The lighting portion 230 of the stair light727644.00845may overhang the front trim panel 133.
[0131] Referring to FIGS. 22-27, a stair module co-packaging assembly 103 may comprise a pair of stair modules 102, including a first stair module 102a and a second stair module 102b. The first stair module 102a may be placed in co-packaged engagement with the second stair module 102b. In the co-packaged engagement, the upper outboard surfaces 146 of the stair modules 102 may be disposed oppositely of one another. In the co-packaged engagement, the lower portions 124 of the stair modules 102 may engagingly receive one another. This configuration may be volumetrically efficient for transport and storage, as shown in FIG. 25A.
[0132] The following listing matches certain terminology used within this disclosure with corresponding reference numbers used in the non-limiting embodiments illustrated in the several figures.100 modular stair system102 stair module102a first stair module102b second stair module102c third stair module102d first co-lateral stair module102e second co-lateral stair module102f lower adjacent stair module102g co-lateral stair module102h co-packaged stair module103 co-packaging assembly104 stair support substructure106 flooring support tray108 floor panel109 spacer receiving edge groove110 pedestal727644.00845111 joist112 cross-bracing element113 upward direction114 annular flange (of pedestal)115 downward direction116 vertical axis (of stair module)117 forward end (of stair module)118 longitudinal axis (of stair module) 119 rearward end (of stair module)120 lateral axis (of stair module)121 lateral end (of pair of lateral ends) 122 upper panel (of stair module)124 lower portion (of stair module)126 front panel (of stair module)128 rear panel (of stair module)130 lateral panel (of stair module)130a right lateral panel130b left lateral panel131 lateral trim panel132 glue channel (of upper panel)133 front trim panel134 longitudinal offset distance138 upper forward edge (of stair module) 140 lower forward edge (of stair module) 142 upper rear edge (of stair module)144 lower rear edge (of stair module)145 upper lateral edge (of stair module) 146 upper outboard surface (of upper panel) 147 lower lateral edge (of stair module) 148 upper inboard surface (of upper panel) 150 front outboard surface (of front panel)727644.00845152 front inboard surface (of front panel)154 lateral outboard surface (of lateral wall)156 lateral inboard surface (of lateral wall)158 forward support section (of lower portion) 160 rearward support section (of lower portion) 161 rearward support distance162 intermediate support section (of lower portion) 163 intermediate support distance164 transitional section (of lower portion)165 acute angle (of transitional section)166 forward support distance168 tray support lip170 lateral hanger mount aperture171 forward hanger mount aperture174 forward bracket mount aperture176 lateral bracket mount aperture178 forward fastener access relief179 access relief floor180 forward fastener aperture181 forward fastener182 upper longitudinal alignment track183 upper array of alternating teeth and grooves 184 lower longitudinal alignment track185 lower array of alternating teeth and grooves 186 coupler aperture187 coupler storage aperture188 upper adhesive aperture189 adhesive rib190 forward adhesive aperture192 lateral adhesive aperture194 stair light relief727644.00845195 access channel lower mouth196 coupler access channel197 access channel upper mouth198 spacer mount aperture199 chamber mouth200 securement block chamber201 track boss202 pedestal engagement portion204 pedestal alignment lip206 pedestal securement clip207 rib substructure208 longitudinal rib210 spar rib212 lateral rib214 fascia clip216 horizontal frame member218 coupler element220 coupler pin222 coupler clip224 retention bracket224a forward retention bracket224b lateral retention bracket228 stair light229 relief engagement portion (of stair light) 230 lighting portion (of stair light)232 flooring securement block234 flooring securement fastener252 clip mount aperture260 base element (of pedestal)262 stair support element (of pedestal) 264 upper annular flange (of pedestal)727644.00845266 pedestal tube267 auxiliary pedestal flange268 pedestal axis269 attachment aperture (of auxiliary pedestal flange) 270 co-packaging relief slot272 rib receiving width274 track boss receiving width280 mountable flooring spacer282 fastenable spacer283 panel insertion portion (of fastenable flooring spacer) 284 spacer fastener290 trim hanger290a front trim hanger290b lateral trim hanger300 pedestal interface portion (of fascia clip)302 slot (of pedestal interface portion)304 pin alignment aperture (of pedestal interface portion) 306 fascia fastener element307 fastener pin (of fascia fastener element)308 frame member interface portion (of fascia clip) 309 frame member support lip312 mount portion (of retention bracket)314 retention portion (of retention bracket)322 mount portion (of trim hanger)324 hang portion (of trim hanger)330 frame member trim hanger332 mount portion (of frame member trim hanger)334 hang portion (of frame member trim hanger)336 stack of co-packaged stair modules727644.00845
[0133] While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.
Claims
727644.00845WHAT IS CLAIMED IS:
1. A stair module comprising:(a) a forward end and a rearward end disposed oppositely of one another;(b) an upper panel spanning between the forward end and the rearward end, a longitudinal axis being defined as extending parallel to the upper panel from the rearward end through the forward end, a vertical axis being defined perpendicularly to the upper panel, the upper panel including one or more upper longitudinal alignment tracks; and(c) a lower portion disposed oppositely of the upper panel, the lower portion including one or more lower longitudinal alignment tracks;wherein the stair module is configured to be placed in mutual modular engagement with a lower adjacent said stair module whereby(i) a longitudinal offset distance is defined between the forward end of the stair module and the forward end of the lower adjacent stair module;(ii) the one or more lower longitudinal alignment tracks of the stair module are in mutual track engagement with respective said upper longitudinal alignment tracks of the lower adjacent stair module, the mutual track engagement being selectably positionable to adjust the longitudinal offset distance;(iii) the mutual track engagement restricts linear movement between the stair module and the lower adjacent stair module along the longitudinal axis of the stair module; and(iv) the mutual track engagement restricts rotational movement between the stair module and the lower adjacent stair module about the vertical axis of the stair module.
2. The stair module of claim 1, wherein(a) the one or more lower longitudinal alignment tracks each comprise a lower array of alternating teeth and grooves;(b) the one or more upper longitudinal alignment tracks each comprise an upper array of alternating teeth and grooves; and(c) for each said mutual track engagement, the lower array of the lower longitudinal alignment track is in intermeshing engagement with the upper array of the upper727644.00845longitudinal alignment track.
3. The stair module of claim 1, wherein the upper panel is configured to be in floor supporting engagement with a floor panel.
4. The stair module of claim 3, wherein(a) a plurality of upper adhesive apertures extends through the upper panel; and (b) the floor supporting engagement is securable at least by way of adhesive bonding between the floor panel and the upper adhesive apertures.
5. The stair module of claim 4, further comprising a multiplicity of adhesive ribs extending beneath respective sets of the upper adhesive apertures.
6. The stair module of claim 3, wherein the floor supporting engagement is securable at least by way of one or more flooring securement fasteners in threaded engagement with the upper panel.
7. The stair module of claim 6, further comprisingone or more securement block chambers, each of the securement block chambers (i) disposed between the upper panel and a corresponding said lower longitudinal alignment track;(ii) including a chamber mouth at the upper panel;(iii) configured to receive a flooring securement block by way of the chamber mouth; and(iv) configured to retain the flooring securement block therein;wherein the floor supporting engagement is securable at least by way of the one or more flooring securement fasteners being in threaded engagement with one or more said flooring securement blocks.
8. The stair module of claim 3, wherein the upper panel includes one or more spacer mount apertures each configured to mountingly retain a flooring spacer.727644.008459. The stair module of claim 1, comprising a plurality of pedestal engagement portions, each of the pedestal engagement portions(a) having one or more pedestal securement clips configured to releasably secure an upper annular flange of a pedestal to the pedestal engagement portion; and (b) being disposed on an upper inboard surface of the upper panel.
10. The stair module of claim 9, wherein each of the pedestal engagement portions include a pedestal alignment lip configured to aligningly receive an upper annular flange of a pedestal.
11. The stair module of claim 1, comprising one or more stair light reliefs, each of the stair light reliefs(a) being disposed along an upper forward edge of the upper panel; and(b) configured to receivably engage a relief engagement portion of a stair light.
12. The stair module of claim 1, comprising a rib substructure disposed between the upper panel and the lower portion.
13. The stair module of claim 12, whereinthe stair module includes(a) a lateral axis being defined perpendicularly to the longitudinal axis and the vertical axis; and(b) a pair of lateral ends disposed oppositely of one another along the lateral axis; the rib substructure includes(a) one or more longitudinal ribs extending longitudinally between the forward end and the rearward end;(b) one or more spar ribs extending laterally between the lateral ends; and(c) one or more lateral ribs intersecting at least a set of the longitudinal ribs.
14. The stair module of any one of claims 1-13, further comprising a front panel extending from the upper panel to the lower portion at the forward end.727644.0084515. The stair module of claim 14, wherein(a) a plurality of forward hanger mount apertures extends through the front panel; and (b) the forward hanger mount apertures are each configured to mountingly receive a front trim hanger.
16. The stair module of claim 15, wherein at least a subset of the forward hanger mount apertures is arranged in one or more laterally-distributed rows.
17. The stair module of claim 16, wherein a plurality of the laterally-distributed rows are vertically offset from one another.
18. The stair module of claim 14, wherein(a) a plurality of forward bracket mount apertures extends through the upper panel along an upper forward edge; and(b) the forward bracket mount apertures are each configured to mountingly receive a forward retention bracket.
19. The stair module of claim 14, wherein(a) a plurality of forward adhesive apertures extends through the front panel; and (b) the forward adhesive apertures are configured to facilitate an adhesive bond between the front panel and a front trim panel.
20. The stair module of claim 14 includingone or more forward fastener access reliefs, each of the forward fastener access reliefs (i) being disposed between the upper panel and the lower portion at the forward end;(ii) including an access relief floor extending from a lower forward edge of the front panel; and(iii) configured to allow access to a forward fastener aperture disposed on the access relief floor;wherein the stair module is configured to be secured to the lower adjacent stair module by way of one or more forward fasteners extending through respective said forward fastener apertures.727644.0084521. The stair module of claim 14, further comprising a pair of lateral panels disposed oppositely of one another along a lateral axis, the lateral axis being defined orthogonally to the longitudinal axis and to the vertical axis.
22. The stair module of claim 21, wherein, for each of the lateral panels(a) a plurality of lateral hanger mount apertures extends through the lateral panel; and (b) the lateral hanger mount apertures are each configured to mountingly receive a lateral trim hanger.
23. The stair module of claim 22, wherein at least a subset of the lateral hanger mount apertures is arranged in one or more longitudinally-distributed rows.
24. The stair module of claim 23, wherein a plurality of the longitudinally-distributed rows are vertically offset from one another.
25. The stair module of claim 21, wherein, for each of the lateral panels(a) a plurality of lateral bracket mount apertures extends through the upper panel along an upper lateral edge of the lateral panel; and(b) the lateral bracket mount apertures are each configured to mountingly receive a lateral retention bracket.
26. The stair module of claim 21, wherein, for each of the lateral panels(a) a plurality of lateral adhesive apertures extend through the lateral panel; and (b) the lateral adhesive apertures are configured to facilitate an adhesive bond between the lateral panel and a lateral trim panel.
27. The stair module of claim 21, whereinfor each of the lateral panels(i) one or more coupler apertures extend through the lateral panel; and (ii) the one or more coupler apertures are each configured to have a coupler element extending therethrough; andthe stair module is configured to be placed in coupled engagement with a co-lateral said stair module, whereby(i) a right said lateral panel of the co-lateral stair module is positioned laterally727644.00845adjacent of a left said lateral panel of the stair module; and(ii) one or more axially aligned pairs of the coupler apertures have a coupler element extending therethrough, the one or more axially aligned pairs being defined as the one or more coupler apertures of the right lateral panel of the co-lateral stair module in axial alignment with the one or more coupler apertures of the left lateral panel of the stair module.
28. The stair module of claim 27, comprising, at each lateral wall,one or more coupler access channels(i) disposed laterally inboard of the lateral panel;(ii) in communication with one or more said coupler apertures; and(iii) including an access channel upper mouth at the upper panel.
29. The stair module of claim 28, wherein, at each lateral wall,at least a portion of the coupler access channels each includes an access channel lower mouth at the lower portion.
30. The stair module of claim 21, further comprising a rear panel extending from the upper panel toward the lower portion at the rearward end.
31. The stair module of claim 30, further comprising a tray support lip extending from the rear panel, wherein the tray support lip is configured to engage a flooring support tray at the rearward end.
32. The stair module of claim 31, wherein the tray support lip is disposed at a rearward support distance from the upper panel.
33. The stair module of claim 32, wherein(a) the stair module is configured to be placed in co-packaged engagement with a copackaged said stair module;(b) the tray support lip includes a plurality of co-packaging relief slots; and(c) when in the co-packaged engagement,(i) the tray support lip of the stair module is configured to be received by the lower portion of the co-packaged stair module; and727644.00845(ii) the lower portion of the stair module is configured to receive the tray support lip of the co-packaged stair module.
34. The stair module of claim 33, whereina first set of said co-packaging relief slots(i) have a rib receiving width; and(ii) are each configured to receivably engage a longitudinal rib of the co-packaged stair module.
35. The stair module of claim 34, whereina second set of said co-packaging relief slots(i) have a track boss receiving width; and(ii) are each configured to receivably engage a track boss of the co-packaged stair module; andthe stair module has one or more track bosses each extending from the upper panel to a respective said lower longitudinal alignment track.
36. The stair module of claim 30, wherein(a) the lower portion includes a forward support section, a rearward support section, and an intermediate support section therebetween;(b) the forward support section is disposed at a forward support distance from the upper panel;(c) the rearward support section is disposed at a rearward support distance from the upper panel; and(d) the intermediate support section is disposed at an intermediate support distance from the upper panel, the intermediate support distance being less than the forward support distance and greater than the rearward support distance.
37. The stair module of claim 36, wherein the forward support section, the rearward support section, and the intermediate support section are each parallel to the upper panel, each being configured to supportedly engage a joist.727644.0084538. The stair module of claim 36, wherein(a) the lower portion includes a transitional section disposed between the rearward support section and the intermediate support section; and(b) the transitional section is oriented at an acute angle with respect to the upper panel.
39. A modular stair system comprising:a plurality of stair modules individually including(a) a forward end and a rearward end disposed oppositely of one another;(b) an upper panel spanning between the forward end and the rearward end, a longitudinal axis being defined as extending parallel to the upper panel from the rearward end through the forward end, a vertical axis being defined perpendicularly to the upper panel, the upper panel including one or more upper longitudinal alignment tracks; and(c) a lower portion disposed oppositely of the upper panel, the lower portion including one or more lower longitudinal alignment tracks;wherein a first said stair module is configured to be placed in mutual modular engagement with a second said stair module positioned thereunder, whereby (i) a first longitudinal offset distance is defined between the forward end of the first stair module and the forward end of the second stair module;(ii) the one or more lower longitudinal alignment tracks of the first stair module are in mutual track engagement with the one or more upper longitudinal alignment tracks of the second stair module, the mutual track engagement being selectably positionable to adjust the first longitudinal offset distance; (iii) the mutual track engagement restricts linear movement between the first stair module and the second stair module along the longitudinal axis of the first stair module; and(iv) the mutual track engagement restricts rotational movement between the first stair module and the second stair module about the vertical axis of the first stair module.
40. The modular stair system of claim 39, including a third said stair module, wherein the second stair module is configured to be placed in mutual modular engagement with the third stair module positioned thereunder, whereby727644.00845(i) a second longitudinal offset distance is defined between the forward end of the second stair module and the forward end of the third stair module;(ii) the one or more lower longitudinal alignment tracks of the second stair module are in mutual track engagement with the one or more upper longitudinal alignment tracks of the third stair module, the mutual track engagement of the second stair module and the third stair module being selectably positionable to adjust the second longitudinal offset distance;(iii) the mutual track engagement of the second stair module and the third stair module restricts linear movement therebetween along the longitudinal axis of the second stair module; and(iv) the mutual track engagement of the second stair module and the third stair module restricts rotational movement therebetween about the vertical axis of the second stair module.
41. The modular stair system of claim 39, further comprising one or more flooring support trays, wherein(a) each stair module has a tray support lip extending from its rearward end; and (b) the first stair module is configured to be placed in tray supporting engagement with a said flooring support tray by way of its tray support lip.
42. The modular stair system of any one of claims 39-41, whereinfor each of the stair modules(i) the one or more lower longitudinal alignment tracks each comprises a lower array of alternating teeth and grooves; and(ii) the one or more upper longitudinal alignment tracks each comprises an upper array of alternating teeth and grooves; andfor each said mutual track engagement, the lower array of the lower longitudinal alignment track is in intermeshing engagement with the upper array of the upper longitudinal alignment track.
43. The modular stair system of any one of claims 39-41, further comprising one or more floor panels, wherein, for each of the stair modulesthe upper panel is configured to be placed in floor supporting engagement with a said floor panel.727644.0084544. The modular stair system of claim 43, wherein, for each of the stair modules(a) a plurality of upper adhesive apertures extends through the upper panel; and (b) the floor supporting engagement is securable at least by way of adhesive bonding between the floor panel and the upper adhesive apertures.
45. The modular stair system of claim 44, wherein, for each of the stair modules, the upper panel comprises a multiplicity of adhesive ribs extending beneath respective sets of the upper adhesive apertures.
46. The modular stair system of claim 43, further comprising a plurality of flooring securement fasteners, wherein, for each of the stair modules, the floor supporting engagement is securable at least by way of a first set of the flooring securement fasteners being in threaded engagement with the upper panel.
47. The modular stair system of claim 46, further comprising a plurality of flooring securement blocks,the stair modules individually comprisingone or more securement block chambers, each of the securement block chambers (i) being disposed between the upper panel and a corresponding said lower longitudinal alignment track;(ii) including a chamber mouth at the upper panel;(iii) configured to receive a said flooring securement block by way of the chamber mouth; and(iv) configured to retain the flooring securement block therein; and wherein, for each of the stair modules, the floor supporting engagement is securable at least by way of a second set of the flooring securement fasteners being in threaded engagement with the flooring securement blocks retained in the securement block chambers.
48. The modular stair system of claim 43, further comprising a plurality of mountable flooring spacers, wherein(a) for each of the stair modules, the upper panel includes one or more spacer mount apertures, each of the spacer mount apertures being configured to mountingly retain one of the mountable flooring spacers; and727644.00845(b) each of the mountable flooring spacers is configured to be placed in mounted spacing communication between a coplanar arranged pair of said floor panels.
49. The modular stair system of claim 43, further comprising a plurality of front trim panels, wherein, for each of the stair modules(a) a front panel extends from the upper panel to the lower portion at the forward end;and(b) a said front trim panel is configured to be disposed in forward affixed engagement with the front panel.
50. The modular stair system of claim 49, further comprising a plurality of front trim hangers, wherein, for each of the stair modules(a) the front panel includes a plurality of forward hanger mount apertures;(b) the forward hanger mount apertures are each configured to mountingly receive a said front trim hanger; and(c) the forward affixed engagement is configured to be at least in part by way of a subset of the front trim hangers in hanging receipt of the front trim panel.
51. The modular stair system of claim 50, wherein, for each of the stair modules(a) at least a portion of the forward hanger mount apertures are arranged in laterally- distributed rows; and(b) the laterally-distributed rows are vertically offset from one another, facilitating selectable vertical positioning of the front trim panel relative to the front panel.
52. The modular stair system of claim 49, further comprising a plurality of forward retention brackets, wherein, for each of the stair modules(a) a plurality of forward bracket mount apertures extend through the upper panel along an upper forward edge of the front panel;(b) the forward bracket mount apertures are each configured to mountingly receive a said forward retention bracket; and(c) the forward affixed engagement is configured to be at least in part by way of a subset of the forward retention brackets in forward restraint of the front trim panel.727644.0084553. The modular stair system of claim 49, wherein, for each of the stair modules(a) a plurality of forward adhesive apertures extend through the front panel; and (b) the forward affixed engagement is configured to be at least in part by way of adhesive bonding between the front trim panel and the forward adhesive apertures.
54. The modular stair system of claim 49, the stair modules individually including one or more forward fastener access reliefs, each said forward fastener access relief (i) being disposed between the upper panel and the lower portion at the forward end;(ii) including an access relief floor extending from a lower forward edge of the front panel; and(iii) configured to allow access to a forward fastener aperture disposed on the access relief floor;wherein, for each said mutual modular engagement, a corresponding pair of said stair modules are configured to be secured to one another at least by way of one or more forward fasteners extending through respective said forward fastener apertures.
55. The modular stair system of claim 49, comprising a plurality of lateral trim panels, wherein, for each of the stair modules(a) a pair of lateral panels are disposed oppositely of one another along a lateral axis, the lateral axis being defined orthogonally to the longitudinal axis and to the vertical axis; and(b) for each of the lateral panels, a said lateral trim panel is configured to be disposed in lateral affixed engagement with the lateral panel.
56. The modular stair system of claim 55, further comprising a plurality of lateral trim hangers, wherein, for each of the stair modules, at each lateral panel,(a) a plurality of lateral hanger mount apertures extend through the lateral panel, each said lateral hanger mount aperture being configured to mountingly receive a said lateral trim hanger; and(b) the lateral affixed engagement is configured to be at least in part by way of a portion of the lateral trim hangers in hanging receipt of the lateral trim panel.727644.0084557. The modular stair system of claim 56, wherein, for each of the stair modules, at each lateral panel,(a) at least a portion of the lateral hanger mount apertures are arranged in longitudinally-distributed rows; and(b) the longitudinally-distributed rows are vertically offset from one another, facilitating selectable vertical positioning of the lateral trim panel relative to the lateral panel.
58. The modular stair system of claim 55, further comprising a plurality of lateral retention brackets, wherein, for each of the stair modules, at each lateral panel,(a) a plurality of lateral bracket mount apertures extend through the upper panel along an upper lateral edge of the lateral panel;(b) the lateral bracket mount apertures are each configured to mountingly receive a said lateral retention bracket; and(c) the lateral affixed engagement is configured to be at least in part by way of a portion of the lateral retention brackets in lateral restraint of the lateral trim panel.
59. The modular stair system of claim 55, wherein, for each of the stair modules, at each lateral panel,(a) a plurality of lateral adhesive apertures extend through the lateral panel; and (b) the lateral affixed engagement is configured to be at least in part by way of adhesive bonding between the lateral trim panel and the lateral adhesive apertures.
60. The modular stair system of claim 55, further comprising a plurality of fastenable spacers, wherein(a) the fastenable spacers are each configured to be placed in fastened engagement with a said stair module at the upper panel, the front panel, or one of the lateral panels; and(b) for each fastened engagement, the fastenable spacer is in fastened spacing communication between a corresponding pair of coplanar arranged said floor panels, a corresponding pair of coplanar arranged said front trim panels, or a corresponding pair of coplanar arranged said lateral trim panels.727644.0084561. The modular stair system of claim 60, wherein(a) each of the fastenable spacers includes a panel insertion portion;(b) a set of the floor panels, a set of the front trim panels, and a set of the lateral trim panels, each include a spacer receiving edge groove; and(c) for the fastened spacing communication, the panel insertion portion is inserted into a corresponding said spacer receiving edge groove.
62. The modular stair system of claim 39, further comprising a plurality of coupler elementswherein each of the stair modules comprises(i) a pair of lateral panels disposed oppositely of one another along a lateral axis, the lateral axis being defined orthogonally to the longitudinal axis and to the vertical axis, the pair of lateral panels including a right lateral panel and a left lateral panel; and(ii) one or more coupler apertures extending through each said lateral panel; wherein a first co-lateral said stair module is configured to be placed in a first coupled engagement with the first stair module, wherein, for the first coupled engagement (i) the right lateral panel of the first co-lateral stair module is positioned laterally adjacent of the left lateral panel of the first stair module, one or more first axially aligned pairs of coupler apertures being defined as the one or more coupler apertures of the right lateral panel of the first co-lateral stair module in axial alignment with the one or more coupler apertures of the left lateral panel of the first stair module; and(ii) a first set of the coupler elements each being configured to be installed from and removed from a said first axially aligned pair, each coupler element including a coupler pin extending through the first axially aligned pair, and each coupler element including a coupler clip to removably secure the coupler pin;wherein a second co-lateral said stair module is configured to be placed in a second coupled engagement with the second stair module, wherein, for the second coupled engagement(i) the right lateral panel of the second co-lateral stair module is positioned laterally adjacent of the left lateral panel of the second stair module, one or more second axially aligned pairs of coupler apertures being defined as the727644.00845one or more coupler apertures of the right lateral panel of the second co-lateral stair module in axial alignment with the one or more coupler apertures of the left lateral panel of the second stair module; and(ii) a second set of the coupler elements each being configured to be installed from and removed from a said second axially aligned pair, each coupler element including a coupler pin extending through the second axially aligned pair, and each coupler element including a coupler clip to removably secure the coupler pin; andwherein the first co-lateral stair module and the second co-lateral stair module are configured to be placed in mutual modular engagement with one another.
63. The modular stair system of claim 62, wherein each of the stair modules includes, at each lateral panelone or more coupler access channels(i) disposed laterally inboard of the lateral panel;(ii) being in communication with one or more of the coupler apertures;(iii) including an access channel upper mouth at the upper panel; and(iv) including an access channel lower mouth at the lower portion.
64. The modular stair system of any one of claims 39-41 and 62-63, further comprising a stair support substructure configured to be placed in stair supporting engagement with the stair modules.
65. The modular stair system of claim 64, wherein the stair support substructure comprises a plurality of pedestals, each pedestal having a base element, a stair support element with an upper annular flange, and a pedestal tube extending therebetween along a pedestal axis, wherein(a) for each of the stair modules(i) an upper inboard surface of the upper panel includes one or more pedestal engagement portions;(ii) each of the pedestal engagement portions includes a pedestal alignment lip;and(iii) each said pedestal alignment lip includes one or more pedestal securement clips; and727644.00845(b) the stair modules are configured to be placed in the stair supporting engagement by way of one or more of their respective pedestal engagement portions each being secured to a stair support element, the corresponding pedestal securement clips retaining the respective upper annular flange in the respective pedestal alignment lip.
66. The modular stair system of claim 65, further comprising a plurality of fascia clips and a plurality of horizontal frame members, wherein(a) each said fascia clip has a pedestal interface portion and frame member interface portion;(b) one or more of the pedestals each includes an auxiliary pedestal flange through which a plurality of attachment apertures extend;(c) each said pedestal interface portion including(i) a slot configured to engageably receive a said auxiliary pedestal flange;(ii) at least one pin alignment aperture intersecting the slot; and(iii) a corresponding fascia fastener element configured to be manually installed in and removed from the pedestal interface portion, each said fascia fastener element including at least one fastener pin configured to extend through a respective said pin alignment aperture and a respective said attachment aperture when the fascia fastener element is installed; and(d) each of the frame member interface portions include a frame member support lip configured to receivably engage a said horizontal frame member.
67. The modular stair system of claim 66, further comprising a plurality of frame member trim hangers configured to be mountably secured to a said horizontal frame member, the frame member trim hangers each being configured to be in hanging receipt of a lateral trim panel.
68. The modular stair system of claim 64, wherein the stair support substructure comprises a plurality of joists, wherein(a) for each of the stair modules, the lower portion has a forward support section, an intermediate support section, and a rearward support section, each being parallel to the upper panel; and(b) each said joist is configured to be placed in joist supporting engagement with a said727644.00845forward support section, a said intermediate support section, or a said rearward support section.
69. The modular stair system of any one of claims 39-41 and 62-63, further including a plurality of stair lights, wherein(a) for each of the stair modules, the upper panel includes one or more stair light reliefs along its upper forward edge; and(b) the stair lights each having a relief engagement portion and a lighting portion, the relief engagement portion configured to be insertably received by a said stair light relief.
70. A stair module co-packaging assembly comprising:a pair of stair modules individually including(a) a forward end and a rearward end disposed oppositely of one another;(b) an upper panel spanning between the forward end and the rearward end, a longitudinal axis being defined as extending parallel to the upper panel from the rearward end through the forward end, a lateral axis being defined as extending parallel to the upper panel and perpendicularly to the longitudinal axis, and a vertical axis being defined perpendicularly to the upper panel, the upper panel including one or more upper longitudinal alignment tracks, and the upper panel having an upper outboard surface;(c) a lower portion disposed oppositely of the upper panel, the lower portion including one or more lower longitudinal alignment tracks;wherein a first said stair module is configured to be placed in mutual modular engagement with a second said stair module positioned thereunder, whereby (i) a first longitudinal offset distance is defined between the forward end of the first stair module and the forward end of the second stair module;(ii) the one or more lower longitudinal alignment tracks of the first stair module are in mutual track engagement with the one or more upper longitudinal alignment tracks of the second stair module, the mutual track engagement being selectably positionable to adjust the first longitudinal offset distance; (iii) the mutual track engagement restricts linear movement between the first stair module and the second stair module along the longitudinal axis of the first stair module; and727644.00845(iv) the mutual track engagement restricts rotational movement between the first stair module and the second stair module about the vertical axis of the first stair module; andwherein the first stair module is configured to be placed in co-packaged engagement with the second stair module, wherein, in the co-packaged engagement, (i) the upper outboard surfaces of the stair modules are disposed oppositely of one another; and(ii) the lower portions of the stair modules engagingly receive one another.
71. The stair module co-packaging assembly of claim 70, whereinfor each of the stair modules(i) a rear panel extends from the upper panel toward the lower portion at the rearward end;(ii) a tray support lip extends from the rear panel; and(iii) the tray support lip includes a plurality of co-packaging relief slots; and for the co-packaged engagement(i) the tray support lip of the first stair module is configured to be received by the lower portion of the second stair module; and(ii) the lower portion of the first stair module is configured to receive the tray support lip of the second stair module.
72. The stair module co-packaging assembly of claim 71, wherein, for each of the stair modules(a) a rib substructure is disposed between the upper panel and the lower portion, including one or more longitudinal ribs extending between the forward end and the rearward end; and(b) the tray support lip includes a first set of said co-packaging relief slots(i) having a rib receiving width; and(ii) each being configured to receivably engage a said longitudinal rib of the other said stair module when configured in the co-packaged engagement.
73. The stair module co-packaging assembly of claim 72, wherein, for each of the stair modules(a) one or more track bosses each extends from the upper panel to a respective said727644.00845lower longitudinal alignment track; and(b) the tray support lips include a second set of said co-packaging relief slots(i) having a track boss receiving width; and(ii) each being configured to receivably engage a track boss of the other stair module when configured in the co-packaged engagement.