Attic Stair Support Beam Assembly With Locking End Caps
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Solution Overview
Problem
Existing attic stairs with support beams positioned in recesses on the stringers are cumbersome to assemble and transport due to their complex design, limiting flexibility and ease of attachment.
Innovation Solution
A foldable ladder with a support beam featuring end caps and locking pins for easy assembly, allowing for quick attachment and detachment of ladder segments, and a durable connection between flat bars and the support beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the support beam is positioned in recesses on the stringers with ear brackets and bolts, then the distance between the hatch and the first segment of the stairs is minimized, but the assembly process becomes cumbersome and complex
Solution Approach 1:
The support beam is divided into modular segments that can be independently assembled. Each segment includes integrated ear brackets and mounting features that allow for simplified assembly without requiring complex recesses or multiple fastening operations. This segmentation enables easier transport and assembly while maintaining the desired spatial configuration.
Solution Approach 2:
The ear brackets and mounting features are merged directly into the support beam structure itself, eliminating the need for separate recesses in the stringers. This integration combines multiple functions (support, positioning, and fastening) into a single component, significantly simplifying the assembly process while achieving the same spatial result.
2Ease of manufacture
If the support beam and recess in the stringers are made rectangular and flush without play, then single ear brackets can be used for attachment, but the design becomes less flexible for various sizes and configurations
Solution Approach 1:
The support beam design incorporates universal mounting features that can accommodate various stringer configurations and sizes. The integrated ear brackets and mounting mechanisms are designed to work with different rectangular recess configurations, allowing the same basic design to adapt to various attic stair configurations without requiring custom modifications.
Solution Approach 2:
While maintaining the overall simple rectangular profile, the design incorporates localized variations in the ear bracket geometry and mounting feature placement to accommodate different stringer thicknesses and configurations. This allows a single standardized beam design to fit multiple applications while maintaining the simplicity of the overall structure.
3Ease of operation
If the support beam is designed with integrated ear brackets and mounting features, then assembly is simplified, but the transportability and ease of movement are reduced
Solution Approach 1:
The support beam is designed as a modular assembly that can be divided into smaller segments for transport. Each segment includes its own integrated mounting features, allowing for easy reassembly at the destination. This segmentation reduces the size and weight of individual components during transport while maintaining the simplicity of the final assembled structure.
Data Source
AI summary
Attic stairs include box, closing hatch for the box and ladder. The ladder is suspended in box using at least one flat bar attached to support beam seated in an upper section of the ladder. The support beam is a profile and each end of the profile has end cap with locking pin locking it in support beam.