Modular Stair System with Orthogonal Fastening Brackets
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Solution Overview
Problem
Conventional stair systems for outdoor structures are resource-intensive and technically challenging to assemble, often resulting in defective or aesthetically unpleasing systems due to precise measurement and cutting requirements, and excessive use of fasteners.
Innovation Solution
The proposed stair system includes a perimeter frame member with structural features and stair tread brackets that facilitate interaction between components, providing increased structural integrity and reducing installation errors through orthogonal fastening brackets and tread supports, which aid in alignment and securing of stair tread members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional lumber construction methods are used, then structural strength can be achieved, but assembly complexity and resource consumption increase significantly
Solution Approach 1:
The stair system is divided into modular components including perimeter frame members, stair tread brackets, and stair tread members that can be assembled separately. Each component is designed as a discrete unit with standardized connection interfaces, allowing for simplified assembly while maintaining overall structural strength.
Solution Approach 2:
The bracket assembly combines multiple functions into a single component: it provides structural support for stair tread members, serves as a connection element between perimeter frame members, and incorporates fastening features. This merging reduces the number of separate parts and simplifies the assembly process.
2Strength
If traditional lumber construction methods are used, then structural strength can be achieved, but the number of fasteners and assembly time increase
Solution Approach 1:
The bracket assembly integrates support functions and fastening functions into a single component structure. The bracket itself serves as both the support element and the fastening mechanism, eliminating the need for separate fasteners in many cases and reducing overall fastener quantity while maintaining structural strength.
Solution Approach 2:
The bracket acts as an intermediary component between the perimeter frame members and stair tread members, providing a standardized interface that simplifies connection. This intermediary structure reduces the need for multiple fasteners by incorporating connection features directly into the bracket design.
3Manufacturing precision
If precise measurements and cuts are required, then assembly accuracy improves, but assembly difficulty and error rates increase
Solution Approach 1:
The perimeter frame members and brackets are pre-manufactured with predetermined dimensions, angles, and connection features. This preliminary preparation of components with standardized geometries eliminates the need for precise measurements and cuts during assembly, while maintaining high assembly accuracy through consistent pre-fabricated dimensions.
Solution Approach 2:
The bracket assembly serves multiple functions including support, connection, and alignment, with standardized interfaces that work across different components. This universality reduces assembly difficulty by providing consistent connection methods while maintaining accuracy through standardized geometries that eliminate the need for custom measurements.
4Stability of the object's composition
If conventional stair systems are used, then structural integrity can be achieved, but installation time and resource consumption increase
Solution Approach 1:
The stair system is segmented into pre-manufactured modular components with standardized connection interfaces. This segmentation allows for faster assembly by eliminating the need for complex measurements and cuts during installation, while maintaining structural integrity through consistent connection designs that ensure stable assembly.
Solution Approach 2:
Components are pre-manufactured with predetermined dimensions, angles, and connection features during factory production. This preliminary action completes the complex manufacturing and measurement tasks before installation, allowing on-site assembly to focus only on simple connection operations, thereby reducing installation time while preserving structural integrity.
Data Source
AI summary
Stair system for outdoor building structures, such as decks are described. The stair system can include one or more perimeter frame members, one or more stair tread brackets; one or more stair tread members, and one or more fastening brackets coupled to the perimeter frame members, when in an assembled configuration.