Modular Staircase Frame Segmentation for Easy Installation
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Solution Overview
Problem
Conventional staircases are bulky, heavy, and difficult to install, especially in multi-story homes, requiring additional structural elements that limit mass production and lead to costly maintenance and installation challenges.
Innovation Solution
A lightweight, modular staircase frame composed of laterally spaced blades that can be easily transported and assembled, allowing for adjustable attachment to surfaces and removable treads, reducing the need for external structural elements and enabling easier installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a conventional staircase is fabricated off-site and transported to the home, then the staircase provides structural support and connectivity between floors, but it becomes bulky and heavy requiring two or more individuals and special equipment for installation
Solution Approach 1:
The staircase is divided into multiple individual steps that can be manufactured separately and assembled at the installation location. Each step is a discrete component that can be easily handled and positioned, eliminating the need to transport and install a large, heavy monolithic structure. This segmentation allows lightweight individual components to be assembled into a complete staircase system.
2Ease of manufacture
If conventional staircases use wooden stringers or structural elements between floors, then the staircase can be anchored and set at the correct slope, but it limits mass production capability and causes squeaking and creaking during extended use
Solution Approach 1:
The structural elements are changed from traditional wooden stringers to metal components with standardized dimensions and attachment mechanisms. This parameter change enables precise manufacturing tolerances and consistent geometric features that facilitate mass production while maintaining structural integrity. The metal components provide rigid support without the dimensional variations and material inconsistencies of wood.
3Ease of operation
If finished treads are installed from the outset on conventional staircases, then the staircase is complete and ready for use, but the treads are exposed to heavy use by contractors during construction and require costly repairs
Solution Approach 1:
The staircase structure, including support elements and framing, is installed and prepared in advance during the construction phase. However, the finished treads are deliberately left uninstalled until the construction period ends and the home is ready for occupancy. This preliminary preparation of the structural framework allows the fragile finished treads to be installed last, avoiding exposure to construction-related damage and heavy contractor traffic.
Data Source
AI summary
A modular staircase frame is lightweight, adjustable, and may be brought to a worksite in pieces to be assembled. The modular staircase frame includes two opposing sets of laterally spaced blades, which may be adjustably connected to form laterally spaced ascending frame members. The opposing sets of blades may include a first pair of blades and a final pair of blades to anchor the frame to a first and second surface, respectively. The blades have openings for adjustable attachment of adjacent blades. The frame may also include stiffeners for added structural support. The opposing sets of laterally spaced blades may further include one or more corner blades for changing the direction of the staircase. Once the frame is installed, treads (temporary or final) can be removably installed on the frame to create a staircase.