Stair Element Continuous Decorative Layer Foldability
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Solution Overview
Problem
Existing stair elements for stair treads often have gaps between the tread and nose surfaces, and limited design and material choices, which affect their appearance and durability.
Innovation Solution
A stair element with a continuous decorative visual layer extending from the tread to the nose surface, featuring a recess for foldability and a wear layer, allowing for a natural wood or stone appearance and increased design flexibility, and incorporating a protective element for enhanced safety and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a covering material is folded at an acute angle to create a sharp fold line, then the appearance of natural wood or stone is achieved, but the material may break or split due to limited foldability
Solution Approach 1:
The covering is divided into multiple layers, with the substrate layer providing structural support and the decorative visual layer providing the natural appearance. This segmentation allows the substrate to handle the mechanical stress of folding while the decorative layer maintains the visual continuity needed for the sharp fold appearance.
Solution Approach 2:
The covering comprises a composite structure with a substrate and a decorative visual layer. The substrate provides the mechanical properties needed for folding without breaking, while the decorative layer provides the visual appearance of natural materials. This composite structure resolves the contradiction between achieving sharp folds and maintaining material integrity.
2Shape
If the decorative visual layer extends continuously from the tread surface onto the nose surface, then a natural wood or stone appearance is achieved, but manufacturing complexity increases
Solution Approach 1:
The decorative visual layer is applied in a continuous manner that extends across the transition from the tread surface to the nose surface, creating a three-dimensional continuous appearance. This approach achieves the natural material look while the underlying substrate structure simplifies the manufacturing process by providing a stable base for the decorative layer.
3Ease of operation
If a recess is provided in the covering to enable folding, then foldability is improved, but the structural strength of the covering is reduced
Solution Approach 1:
The covering is segmented into a substrate layer and a decorative visual layer. The substrate layer contains the recess that enables folding, while the decorative layer extends continuously over the transition. This segmentation allows the recess to be positioned in the substrate where it provides foldability without significantly compromising the overall structural strength, as the decorative layer maintains continuity.
Data Source
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AI summary
The present invention relates to a stair element for a stair tread, comprising: - a tread surface, - a nose surface which in an orientation of use extends substantially downward relative to the tread surface, and - a covering comprising a decorative visual layer, wherein: - the decorative visual layer extends continuously from at least a part of the tread surface onto the nose surface and wherein the decorative visual layer has substantially a continuous finish over a transition between the tread surface and the nose surface.