Adjustable Stair Step Support Bracket with Positioning Ears
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Solution Overview
Problem
Stair stringer assembly is challenging due to the need for precise positioning of step support brackets on joists to ensure consistent rise and run dimensions, requiring repeated measurements and complex placement processes.
Innovation Solution
The design includes adjustable stair step support brackets with tray support walls and side walls featuring positioning holes for set pins, allowing for easy alignment and secure fastening to joists, accommodating various stair angles and rise dimensions without extensive measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If step support brackets are manually positioned on joists using repeated measurements, then placement precision can be achieved, but assembly complexity and time consumption increase significantly
Solution Approach 1:
The bracket includes pre-formed positioning ears with positioning surfaces that extend beyond the joist surface, allowing the bracket to be automatically positioned at the correct location before fastening. This preliminary positioning structure eliminates the need for repeated measurements during assembly while ensuring precise and consistent placement.
2Manufacturing precision
If precise positioning structures are added to brackets, then placement consistency improves, but bracket complexity and fabrication difficulty increase
Solution Approach 1:
The positioning function is segmented into separate positioning ears that are formed as distinct features on the bracket. These ears can be independently formed using standard sheet metal forming processes, making the positioning structures easier to manufacture while maintaining placement consistency.
Solution Approach 2:
The positioning ears are located only at the specific regions where positioning is needed, rather than requiring precision throughout the entire bracket. The positioning surfaces on the ears provide the necessary precision locally at the joist interface, while the rest of the bracket can be manufactured using standard processes.
3Manufacturing precision
If brackets are designed for specific rise dimensions, then placement accuracy improves, but adaptability to different stair configurations decreases
Solution Approach 1:
The bracket design allows for adjustment of the positioning ears to accommodate different rise dimensions. The ears can be repositioned or adjusted along the bracket body, enabling the same bracket design to be used for multiple stair configurations while maintaining placement accuracy for each specific application.
Solution Approach 2:
The bracket is designed with universal features including adjustable positioning ears and standardized fastening holes that can accommodate various joist positions and stair angles. This multi-functional design allows a single bracket type to serve multiple rise dimensions and stair configurations while maintaining precise placement through the positioning ear mechanism.
Data Source
AI summary
A stair assembly includes at least one joist comprising an upper wall, a first lateral wall extending from the upper wall, and a second lateral wall extending from the upper wall. At least one stair step support bracket includes a tray support wall, a first side wall extending from the tray support wall, and a second side wall extending from the tray support wall. The first and second side walls define a pair of first front aligned positioning holes configured to receive a first set pin and a pair of first rear aligned positioning holes configured to receive a second set pin. The pairs of first front and rear aligned positioning holes disposed such that when the first and second set pins received therethrough contact the upper wall of the at least one joist, the tray support wall is positioned at a first rise dimension.