Stair Bracket with Adjustable Spacers for Gap Control
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Solution Overview
Problem
The construction of stairways is inefficient due to the need for multiple trips to handle and secure separate step boards, variability in gap spacing leading to aesthetic issues, and challenges with hidden fasteners that require uncomfortable or injurious positioning to secure boards to stringers.
Innovation Solution
A bracket system with adjustable spacers and a beveled vertical leg that allows for precise gap setting between stair boards and secure fastening to stringers without visible fasteners, enabling efficient installation and improved comfort and safety for installers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple separate step boards are handled and secured individually to the stringer, then the step construction can be completed, but multiple trips up or down the stairway are required which consumes time
Solution Approach 1:
The patent combines multiple step boards into a single pre-assembled unit with all boards attached to a common stringer support structure. This merging eliminates the need to handle and install each board separately, allowing the entire step assembly to be installed in one placement action, thereby eliminating multiple trips and significantly improving installation productivity
2Manufacturing precision
If step boards are spaced to establish a gap between them, then aesthetic appearance can be improved, but using special tools to precisely set the gap requires carrying multiple different tools which is burdensome
Solution Approach 1:
The patent incorporates pre-configured spacers as integral components of the step board assembly during manufacturing. These spacers are precisely positioned to establish the desired gap dimensions between adjacent boards. By performing the gap-setting action during manufacturing rather than during installation, the system eliminates the need for installers to carry and use multiple specialized spacing tools, reducing device complexity while maintaining high manufacturing precision
3Manufacturing precision
If hidden fasteners are used to install step boards, then the upper surface of the boards have no visible fasteners which is aesthetically pleasing, but installers need to crawl under the steps and stringers to get a proper angle which causes discomfort or injury
Solution Approach 1:
The patent inverts the traditional installation approach by pre-attaching all fasteners to the underside of the step board assembly in a factory setting. This allows fasteners to be installed from the accessible top side during assembly, while the hidden fastener configuration is already established. During installation, the complete assembly is placed from above without requiring installers to crawl underneath, eliminating discomfort and injury risks while maintaining the hidden fastener aesthetic
Data Source
AI summary
A bracket and related method to construct stairways is provided. The bracket includes a top horizontal leg having a first width and a first spacer of a first dimension and a second spacer of a smaller second dimension, and a vertical leg joined with the top leg, the vertical leg having a first height, with a ratio of the first width to the first height being at least 1:2. The method can include placing the top leg adjacent an underside of stair boards, selectively altering or not altering the first spacer based on a preselected gap between the boards, fastening the top leg to the underside of the boards with fasteners while the first spacer and/or the second spacer maintains the preselected gap, placing the bracket vertical leg adjacent a stringer, and fastening the vertical leg to the stringer, optionally while the installer remains above the stairway and stringer.