Stairway Tread Riser Assembly Gusset Design
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Solution Overview
Problem
The installation of conventional stairways is time-consuming and prone to mistakes due to the tedious process of notching stringers and attaching individual tread and riser panels, leading to increased costs and inefficiencies.
Innovation Solution
A stairway assembly featuring a uniquely designed gusset that attaches tread and riser panels together, allowing for integral installation on stringers, with the gusset including attachment structures and a line of weakening for bending to position the panels correctly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional stringers are notched out and individual treads and risers are attached, then the stairway structure is formed, but the installation process becomes time-consuming and error-prone
Solution Approach 1:
The stairway is divided into modular units, each consisting of a stringer section with pre-attached tread and riser panels. These modular units can be independently manufactured and then quickly assembled, eliminating the need for on-site notching and individual panel attachment.
Solution Approach 2:
The treads and risers are pre-attached to the stringers in a controlled manufacturing environment before shipment to the installation site. This preliminary assembly ensures precision and allows for quality control, while significantly reducing on-site installation time and complexity.
2Strength
If three stringers are used with notching, then structural support is provided, but the complexity of notching and alignment increases
Solution Approach 1:
The tread and riser panels are merged with the stringer into a single integrated unit. This combination eliminates the need for separate notching operations and individual panel alignments, reducing installation complexity while maintaining structural integrity through the unified design.
3Reliability
If individual treads and risers are attached to stringers, then the stairway components are secured, but mistakes commonly occur during installation
Solution Approach 1:
The attachment of treads and risers to stringers is performed in advance during manufacturing, allowing for precise alignment and secure fastening in a controlled environment. This preliminary action ensures high attachment reliability and eliminates on-site alignment errors.
Solution Approach 2:
The patent employs visual indicators such as colored alignment marks or contrasting colors on the stringer and panel interfaces to guide proper positioning during assembly, ensuring precise alignment and reducing installation mistakes.
Data Source
AI summary
A stairway assembly includes a tread and riser panel attached together by a uniquely designed gusset to form a tread and riser assembly that can be integrally installed on the stringers. In one embodiment, a first portion of the gusset includes a first attachment structure connected to the lower surface of the tread, and a second portion of the gusset has a second attachment structure connected to the lower surface of the riser. The first portion of the gusset extends at an angle from the second portion, with the side edge of the riser overlapping and facing the upper surface of the tread, and said tread side edge faces said gusset. The gusset may include an elongated slot that forms a line of weakening in the gusset. The gusset may be bent about the line of weakening to move the tread and riser into the final position in which the tread is perpendicular to the riser.