Modular Staircase Jig and Bracket System
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Solution Overview
Problem
There is a need for modular staircase systems with variable rises that can be assembled in a code-compliant and simple manner, while also ensuring comfort and aesthetic appeal, as existing systems require significant knowledge and skill to construct and often result in uncomfortable and poorly finished staircases due to the lack of understanding of building codes and comfort rules among contractors and DIY installers.
Innovation Solution
A system comprising a hanger bracket, tread support structures, and jigs that determine the slope, length, and mounting position of stair stringers, allowing for adaptive support and easy assembly, including bendable components to accommodate varying slopes and ensuring code compliance and comfort rules are met.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If purpose-built staircases are constructed with custom-calculated rises, then code compliance and comfort are achieved, but the construction process becomes complex and requires significant knowledge and skill
Solution Approach 1:
The staircase system is divided into modular components including pre-fabricated stringers with pre-marked rise and run measurements, individual tread modules, and standardized brackets. Each module can be independently manufactured and assembled, eliminating the need for custom calculation and fabrication while ensuring code compliance through pre-engineered dimensions.
Solution Approach 2:
Critical measurements and markings for rise, run, and angles are pre-determined and marked on the stringers during manufacturing. Holes for bracket attachment are pre-drilled at correct positions. This preliminary preparation transfers complex calculation work from the installation phase to the manufacturing phase, simplifying on-site assembly while maintaining precision.
2Ease of operation
If modular components are used to simplify assembly, then ease of installation is improved, but achieving uniform step sizes and code compliance becomes more difficult
Solution Approach 1:
The modular brackets are designed with universal features including adjustable positioning along the stringer and standardized attachment mechanisms that work with all tread modules. The standardized hole patterns and mounting interfaces ensure consistent spacing and uniform step dimensions across all modules while maintaining ease of installation through repeatable assembly procedures.
3Strength
If custom stringers are fabricated for each application, then precise fit and structural integrity are achieved, but the manufacturing process becomes time-consuming and skill-intensive
Solution Approach 1:
The stringers are manufactured with standardized parameters including fixed thickness, width, and material specifications that can be produced efficiently using automated cutting and drilling equipment. While the rise and run dimensions vary between applications, these are accommodated through modular bracket positioning rather than custom stringer fabrication, maintaining structural integrity through consistent material properties and connection designs while improving manufacturing efficiency.
Data Source
AI summary
Systems and methods for constructing staircases are described herein. The systems include a stringer hanger bracket for coupling a stair stringer of the staircase to an upper floor, two or more tread support structures and a jig. Each tread support structure is configured to couple a tread to the stair stringer. The jig is configured to determine a mounting position of each of the tread support structures on the stair stringer, determine a mounting position of each of the tread support structures on the stair stringer and/or determine a length of the stair stringer.