WO2019046565A1

WO2019046565A1 - Stair system and manufacturing

Info

Publication number: WO2019046565A1
Application number: PCT/US2018/048826
Authority: WO
Inventors: John Louis Vanker; Michael J. Lastowski
Original assignee: Patco, Llc
Priority date: 2017-08-31
Filing date: 2018-08-30
Publication date: 2019-03-07
Also published as: US20190093367A1

Abstract

In one implementation, a stair system disclosed herein allows for efficient manufacturing and installation of stairs. The stair system includes a stair comprising a plurality of steps, a lower landing rotatably attached to the bottom of the stair, and an upper landing rotatably attached to the top of the stair, wherein each of the upper landing and the lower landing are configured to be attached to vertical posts.

Description

STAIR SYSTEM AND MANUFACTURING Priority Claim

This application claims priority to U.S. Nonprovisional Application Number 16/117,254 entitled "Stair System and Manufacturing" filed on August 30, 2018, which claims priority to U.S. Provisional Application Ser. No. 62/552,476 entitled "Stair System and Manufacturing" filed on August 31, 2017. Each of these applications is hereby incorporated by reference for all that they disclose or teach.

Technical Field

This application is related to building manufacturing and building

construction technology and specifically to manufacturing and construction of buildings using stainless steel components.

Summary

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages of the claimed subject matter will be apparent from the following more particular written Detailed Description of various implementations and implementations as further illustrated in the accompanying drawings and defined in the appended claims.

Implementations described herein provide a stair system that allows for efficient manufacturing and installation of stairs. The stair system includes a stair comprising a plurality of steps, a lower landing rotatably attached to the bottom of the stair, and an upper landing rotatably attached to the top of the stair, wherein each of the upper landing and the lower landing are configured to be attached to vertical posts.

Brief Descriptions of the Drawings

A further understanding of the nature and advantages of the present technology may be realized by reference to the figures, which are described in the remaining portion of the specification. In the figures, like reference numerals are used throughout several figures to refer to similar components. In some instances, a reference numeral may have an associated sub-label consisting of a lower-case letter to denote one of multiple similar components. When reference is made to a reference numeral without specification of a sub-label, the reference is intended to refer to all such multiple similar components.

FIG. 1 illustrates a three-dimensional view of an example stair disclosed herein with stair railings.

FIG. 2 illustrates an alternate three-dimensional view of the example stair disclosed herein from a bottom perspective.

FIG. 3 illustrates a three-dimensional view of an example stair disclosed herein without stair railings.

FIG. 4 illustrates a three-dimensional view of an example stair disclosed herein without stair railings and support posts.

FIG. 5 illustrates a three-dimensional view of an example stair disclosed herein without stair railings and a first landing.

FIG. 6 illustrates an expanded view of joint between a stair and a lower stair landing.

FIG. 7 illustrates an expanded view of joint between a stair and an upper stair landing. FIG. 8 illustrates an alternate view of a stair with upper and lower stair landings.

FIG. 9 illustrates a view of a stair connected with the upper and lower stair landings and laid out in a flat position.

FIG. 10 illustrates an alternative view of landings of the stair disclosed herein.

FIG. 11 illustrates an illustration of a connection between a stair landing to a post.

FIG. 12 illustrates an illustration of a connection of between two stair landings.

FIG. 13 illustrates an example expanded view of the internal components of a landing of a stair system disclosed herein.

FIG. 14 illustrates yet alternative example views of a staircase together with an upper landing, a lower landing and posts.

FIG. 15 illustrates an example expanded view of a connection between a post and a support beam for a stair landing.

FIG. 16 illustrates an alternate view of a stair with upper and lower stair landings.

FIG. 16 illustrates an expanded view of the steps of the stair disclosed herein near a lower landing.

FIG. 18 illustrates an expanded view of the steps of the stair disclosed herein near an upper landing.

FIG. 19 illustrates operations during design and manufacturing of the stair system disclosed herein. FIG. 20 illustrates example views of components of stair assembly during its installation.

FIG. 21 illustrates example sequence of operations for installation of the stair system disclosed herein

FIG. 22 illustrates an alternative example sequence of operations for installation of the stair system disclosed herein.

FIG. 23 illustrates an alternative example sequence of operations for installation of the stair system disclosed herein.

FIG. 24 illustrates yet alternative example sequence of operations for installation of the stair system disclosed herein.

FIG. 25 illustrates various example views of stair assembly and its connections during various states of its installation.

Detailed Descriptions

In designing and engineering a building's structure, many different assemblies (walls, columns, beams, bracing, strapping, and the fasteners that fasten them together) may be needed to form the building's structure and to manage loads and forces. The assemblies may be standardized through a limited number of uniquely designed standardized wall panels, trusses, fasteners, and other framing components, which may be manufactured using an automated technique such as by roll forming steel sheets. This unique and standardized assembly of elements may be used to form the building's structure and may effectively support loads and forces. Furthermore, these standardized assemblies may be useful in reducing the cost and time in designing such buildings. In multi-story residential or commercial buildings, standardized stairwells may be formed by these standardized components. As such, standardized staircases may be configured to fit in the standardized stairwells. The staircases may be pre-fabricated before the staircases are installed in the building.

In the implementations described herein, a staircase and a method for installing the staircase is provided that allows the staircase to be roughly positioned relative to specific anchor point in a stairwell. The bracket provides a hanger tool with positioning bolts that may be used to accurately position the staircase relative to the specific anchor points. Once the staircase is accurately positioned, the staircase is anchored to the stairwell wall using the bracket and pre-installed bolts, and the hanger tool with the positioning bolt may be removed. These implementations are described further with respect to the following figures.

Furthermore, the stair system disclosed herein is highly standardized, which allows the method disclosed herein to make the entire process of design, manufacturing, and installation highly efficient. Specifically, the standardized components of the stair and the railings, allows adjusting stringer length of the stair based on floor-to-floor heights where the stair system is being installed, adjusting tread length and rise height based on floor-to-floor height and stair length, while still keeping the stair parameters in compliance with applicable safety codes, adjusting width of the landings based on dimensions of a stair tower where the stair system is to be installed, etc. Furthermore, the standardized nature of the components of the stair system also allows calculating structural loads carried by stair system as well as structural columns to which the stair system is attached to. One or more computer instructions is capable of producing shop drawings of building including the stair for review by building departments, contractors, etc.

FIG. 1 illustrates a three-dimensional view of an example stair system 100 disclosed herein with stair railings. The stair system 100 may include stairs 102a and 102b that are detachably and rotatably connected to a first upper landing 110, a lower landing 112, and a second upper landing 114. Specifically, the stairs 102a and 102b have several steps 104. The stair 102a is detachably and rotatably connected at one end to the first upper landing 110 and at a second end to the lower landing 112. The lower landing 112 is detachably connected to the second upper landing 114, which is detachably attached to the stair 102b.

Each of the landings 110, 112, 114 may be attached to columns or posts 120 (120a, 120b, 120c, 120d) via supporting beams 130a and 130b. Furthermore, railings 140 and 142 may also be detachably attached to the stairs 102a and 102b and the posts 120. Providing a plurality of components, such as the stairs, the landings, the posts, the supporting beams, and the railings so that they may be detachably attached to each other allows for flexible and efficient installation of the stair system 100. For example, the posts 120 may be the posts of a stair- well and the supporting beams 130a and 130b are attached to the posts 120 such that there is space 150 between the landings 110, 112, 114 and the posts 120, which allows adding drywall between the posts 120 and the stair system 100.

In one example installation of the stair system 100, the supporting beams 130 are attached to columns 120. Subsequently, the landings 110, 112, 114 are installed and attached to the supporting beams 130. The stairs 102, 900 including the steps 104 are attached to the landings 1 10, 112, 114, and railings 140, 142 may be attached to the stairs 102 and the landings 110, 112, 114. Subsequently, a beam (not shown) made of concrete or other material may be installed on the landings 110, 112, 114. The first upper landing 110 may be rotatably attached to the stair 102a using a joining mechanism 160b and the second upper landing 114 may be rotatably attached to the stair 102b using a joining mechanism 160a. In one implementation, the joining mechanisms 160a, 160b may include a pivot hole in the middle that connects one of the stairs 102a, 102b with one of the landings 110-114.

FIG. 2 illustrates an alternate three-dimensional view of the stair system 200 disclosed herein from a bottom perspective. Specifically, the stair system 200 may include stairs 204a and 204b that are detachably and rotatably connected to a first upper landing 210, a lower landing 212, and a second upper landing 214. Specifically, the stairs 204a and 204b have several steps, wherein each of the steps includes a tread and a riser approximately perpendicular to each other. Each of the landings 210, 212, 214 may be attached to columns or posts 220 (220a, 220b, 220c, 220d) via supporting beams 230a and 230b. Furthermore, railings 242a, 242b, and 242c may also be detachably attached to the stairs 204a and 204b and the posts 220. The railings 242a, 242b, and 242c may be used to attach a rail 244 thereto.

The first upper landing 210 may be rotatably attached to the stair 202a using a joining mechanism 260b and the second upper landing 214 may be rotatably attached to the stair 204b using a joining mechanism 260c. In one implementation, the joining mechanisms 260b, 260c may include a pivot hole in the middle that allows to rotatably connect one of the stairs 204a, 204b with one of the landings 210, 212, and 214.

FIG. 3 illustrates a three-dimensional view of a stair system 300 disclosed herein without stair railings. Specifically, the stair system 300 may include a stair 304 that is detachably and rotatably connected to a first upper landing 310, a lower landing 312. The lower landing 312 is attached to a second upper landing 314. Specifically, the stair 304 may have several steps, wherein each of the steps includes a tread 304a and a riser 304b approximately perpendicular to each other. Each of the landings 310, 312, 314 may be attached to columns or posts 320 (320a, 320b, 320c, 320d) via supporting beams 330a and 330b.

The first upper landing 310 may be rotatably attached to the stair 304 using a joining mechanism 360a and the second upper landing 314 may be rotatably attached to a stair 306 using a joining mechanism 360b. In one implementation, the joining mechanisms 360a, 360b may include a pivot hole in the middle that allows to rotatably connect one of the stairs 304, 306 with one of the landings 310, 312, and 314. In one implementation, the joining mechanisms 360a, 360b are provided as part of the landings 310, 312, and 314. Furthermore, the joining mechanisms 360a, 360b may also include additional holes that are aligned with holes in a side plate 350a, 350b of the stairs 304, 306 and riveted to irremovably join the landings 310, 312, and 314 with the stairs 304, 306. For example, the implementation disclosed in FIG. 3 includes 4 such holes surrounding a center pivot hole.

FIG. 4 illustrates a three-dimensional view of a stair system 400 disclosed herein without stair railings and support posts. Specifically, the stair system 400 may include a stair 404 that is detachably and rotatably connected to a first upper landing 410, a lower landing 412. The lower landing 412 is attached to a second upper landing 414. Specifically, the stair 404 may have several steps, wherein each of the steps includes a tread 404a and a riser 404b approximately perpendicular to each other. Each of the landings 410, 412, 414 may be attached to columns or posts via supporting beams 430a and 430b. Furthermore, the first upper landing 410 may be rotatably attached to the stair 404 using a joining mechanism 460a and the second upper landing 414 may be rotatably attached to a stair 406 using a joining mechanism 460b.

FIG. 5 illustrates a three-dimensional view of a stair system 500 disclosed herein without stair railings and a second landing. A lower connection 510 between a stair 504 and a lower landing 512 is disclosed below in further detail in FIG. 6. The upper connection 520 between the stair 504 and an upper landing 516 is disclosed below in further detail in FIG. 7. Furthermore, FIG. 5 also illustrates treads 502 and risers 508 of a step 506 of the stair 504 and a stringer 518 attached to the steps 506. The upper landing 516 is attached to columns 530a and 530b via a supporting beam 532a and the lower landing 512 are attached to columns 530c and 530d via a supporting beam 532b.

FIG. 6 illustrates an expanded view 600 of the joint between a stair 630 and a lower stair landing 610. The lower stair landing 610 is supported by a supporting beam 620 that may be connected to columns of a building. Specifically, various holes pilot 602a, 602b, 602c, 602d, etc., may be used to connect the stair 630 and the lower stair landing 610.

Additionally, various pilot holes 604a, 604b, 604c, etc., may be used to attach the lower stair landing 610 to the supporting beam 620.

FIG. 7 illustrates an expanded view 700 of the joint between a stair 710 and an upper stair landing 730. The upper landing 720 is connected to and supported by a supporting beam 730. The stair 710 and the upper stair landing 730 may be rotatably attached to each other at a pivot 702. This allows an assembly of the stair 710 and the upper stair landing 730 to be aligned to each other in a plane when being delivered from a manufacturing facility to a building site. Once the assembly of the stair 710 and the upper stair landing 730 are ready for installation, the stair 710 may be rotated to cause proper angle between the stair 710 and the upper stair landing 730. At this angle, various pilot holes 704a, 704b, 704c, 704d on a side plate of the upper stair landing 720 are substantially aligned to various pilot holes in a side plate 706 of the stair 710. These pilot holes 704a, 704b, 704c, 704d are used to fixedly attach the stair 710 and the upper stair landing 730.

FIG. 8 illustrates an alternate view 800 of a stair 802 with an upper landing 804 and a lower landing 806. Specifically, the stair 802 is shown at an angle 810 to a plane of the upper landing 804 and the lower landing 806 such that the risers 812 of the stair 802 are substantially perpendicular to a horizontal surface of the building where the stair system 800 is being installed and the treads 814 are substantially parallel to the horizontal surface of the building.

FIG. 9 illustrates a view of a stair assembly 900 connected with the upper and lower stair landings and laid out in a flat position. In one implementation, the stair assembly 900 is loaded on a delivery truck in the flat position as shown in FIG. 9. The stair assembly 900 includes an upper landing 904, a stair 902, and a lower landing 910 such that the stair is rotatably attached to the upper landing 904 and the lower landing 910. The steps 904 of the stair 902 has treads 904a and risers 904b that are substantially perpendicular to each other. However, in this position the treads are not parallel to the surface of the upper landing 904 and the surface of the lower landing 910. In one implementation, for the stair assembly 900, each of the treads 904a and the risers 904b are at substantially 45 degrees from the surface of the upper landing 904 and the surface of the lower landing 910.

The upper landing 904 is rotatably attached to the stair 902 using an upper fastening mechanism 922 whereas the lower landing 910 is rotatably attached to the stair 902 using a lower fastening mechanism 920. For example, the upper fastening mechanism 922 may have a pivot sleeve 930a with bearings that rotatably attaches the upper landing 904 to the stair 902. Similarly, the lower fastening mechanism 922 may have a pivot sleeve 930b with bearings that rotatably attaches the lower landing 910 to the stair 902. When the stair assembly 900 is ready for installation, the upper stair landing 904 may be hooked to crane and lifted up in the direction 940 to cause the stair assembly 900 to move to a position as shown by 950.

FIG. 10 illustrates an alternative view 1000 of landing 1002 of the stair system disclosed herein. A first connection 1010 between the landing 1002 and a post 1008c is disclosed in further detail in FIG. 11 below. A second connection 1020 between the landing 1002 and a support beam 1030 is disclosed in further detail in FIG. 11 below. The support beam 1030 may be attached to another post 1008b and the landing 1002 may also be attached to a post 1008a. The landing 1002 is also shown to be attached to a stair 1006.

FIG. 11 illustrates an illustration of a connection 1100 between a stair landing 1120 and a post 1102. Also illustrated is a supporting beam 1110 that is attached to the post 1102. FIG. 12 illustrates an illustration of a connection 1200 of between a stair landing 1204 and a support beam 1202. Specifically, a fastening plate 1206 may be used to attach the stair landing 1204 and the support beam 1202.

FIG. 13 illustrates an expanded view 1300 of the internal components of a landing 1304 of a stair system disclosed herein. The landing 1304 is attached to a column 1302 and to a support beam 1306. Specifically, the landing 1304 is attached to the support beam 1306 using fastening plates 1310a and 1310b. In this implementation, the support beam 1306 has a shape of an inverted T where the two side flanges of the support beam 1306 are attached to the stair landing 1304 using L shaped fastening plates 1310a and 1310b.

FIG. 14 illustrates yet alternative view of a staircase 1400 together with an upper landing 1410, a lower landing 1420, posts 1402a-1042d, and supporting beams 1430a and 1430b.

FIG. 15 illustrates an expanded view of a connection 1500 between a post 1502 and a support beam 1504 for a stair system. The support beam 1504 may be a T shaped beam with a center flange 1506 that may be attached with the post 1502 using a connector 1508.

FIG. 16 illustrates an alternate view of a stair assembly 1600 with an upper and lower stair landings 1606 and 1604 connected to a stair 1602 having a number of steps 1608. The upper stair landing 1606 may be rotatably attached to the stair 1602 using an upper connector 1610 and an opening 1620 that may be used to support the upper stair landing 1606 on a support beam. The lower stair landing 1604 may be rotatably attached to the stair 1602 using a lower connector 1622 and an opening 1624 that may be used to support the upper stair landing 1606 on a support beam.

FIG. 17 illustrates an expanded view 1700 of a stair 1704 with steps 1710 near a lower stair landing 1702. FIG. 18 illustrates an expanded view 1800 of a stair 1804 with steps 1706 near an upper stair landing 1802.

FIG. 19 illustrates operations 1900 during design and manufacturing of the stair system disclosed herein. An operation 1902 creates a stair placeholder in an architectural model according to the architect requirements. An operation 1904 defines additional parameters of the stair such as preferable number of steps per level, length of the landing, etc. These parameters are verified in real time with all the structural and code rules to make sure that the stair's design is proper and compliant with the codes. In case of non-proper input, the operation 1904 informs a designer about such non-proper input and requests updated value of the parameter.

An operation 1906 solves a building model with the stair parameters received at operation 2004. Such solving of the building model may in involve solving for number of floors/levels, height of each level, size of the shaft to hold the stair (stair-well), other parameters provided by the stair designer, etc. The operation 1906 also translates these parameters into a string of values identifying the stair.

An operation 1908 generates posts and brackets for framing the stair. These posts and brackets are automatically located at three-dimensional location in the building model. The framing including the posts and the brackets is used to support the stair.

An operation 1910 uses the string of values identifying the stair (as generated at operation 2006) as an input to create structural components of stair. Such structural components may include landings, runs, treads, railings, etc. An operation 1912 generates alphanumeric codes for each component of the stair system for manufacturing the

components. Subsequently, an operation 1914 generates outputs such as 3-dimensional stair model, shop drawings for all parts (landings, railings, etc.), shop drawings for all required assemblies, a bill of material, manufacturing files such as a standard exchange of product (STP) file, etc. For example, the operation 2012 may generate shop drawings that may be used for fabrication of the stair components, including shop drawings for the stair treads, landings, railings, etc. Such shop drawings may also be used by building inspectors and building departments for its compliance with appropriate safety codes and regulations.

Another output generated by the operation 2012 may be macro files that may be

communicated to a production machine, such as a cold roll former, to manufacture one or more components of the stair, such as treads, landings, railings, supporting beams, etc. Such macro files allow automation of the process of manufacturing and putting together components used in the stair system. Another output generated by the operation 2012 may be a bill of material for the stair system. Furthermore, each component of the stair system is associated with three-dimensional coordinates where that component is to be installed in a building.

FIG. 20 illustrates a stair assembly 2000 including a bottom flight assembly 2002, a middle flight assembly 2006, and guard rail assemblies 2004 and 2008.

FIG. 21 illustrates sequence of operations 2100 for installation of the stair system disclosed herein. Specifically, at a flat state 1, all transportation bolts are removed, hooks are fastened to both ends of a stair run, and only a side of top landing is raised to the moment when all holes at stringers and upper landings match. At a final state 2 all final bolts are fastened.

FIG. 22 illustrates an alternative sequence of operations 2100 for installation of guard rails to the stair system disclosed herein. At a final state 3 with guard rails, guard rails are attached to the stringer of the stair and all guard rail posts besides the higher one are attached. Subsequently, they are bolted after installation at a shaft of the building. State 4 illustrates rise up crane trying to hold landing horizontally. FIG. 23 illustrates sequence of operations 2300 for installation of the stair system disclosed herein. Specifically, at a flat state 1, all transportation bolts are removed, hooks are fastened to both ends of a stair run, and only a side of top landing is raised to the moment when all holes at stringers and upper landings match. At an intermediate state 2, final bolts are fastened at stringers of the stair and upper landing connections are made. At this state the assembly is raised to a state where only side of top landing to the moment when all holes at stringers and lower endings match.

FIG. 24 illustrates sequence of additional operations 2400 for installation of the stair system disclosed herein. At a final state 3, final bolts are fastened at stringers and lower landing connections are made and whole assembly is put in place. At state 4, guard rails are attached to the stringer of the stair, all middle guard rail posts are attached and first and last post are bolted after installation of the assembly at the shaft of the building.

Subsequently, chains are fastened to the stringer to lower the landing connections. At state 5, chains are adjusted in way so that landings are horizontal.

FIG. 25 illustrates various views 2510, 2512, 2514, 2514, and 2518 of stair assembly and its connections during various states of its installation.

The above specification, examples, and data provide a complete description of the structure and use of exemplary embodiments of the invention. Since many

embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Furthermore, structural features of the different embodiments may be combined in yet another embodiment without departing from the recited claims. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the invention. The implementations described above and other implementations are within the scope of the following claims.

Claims

WHAT IS CLAIMED IS:

1 A stair system, comprising:

a stair comprising a plurality of steps;

a lower landing rotatably attached to the bottom of the stair; and

an upper landing rotatably attached to the top of the stair.

2. The stair system of claim 1, wherein each of the upper landing and the lower landing are configured to be attached to vertical posts.

3. The stair system of claim 1, further comprising one or more railings configured to be detachably attached to the stair, the lower landing, and the upper landing.

4. The stair system of claim 1, the upper landing of a first level is configured to be attached to a lower landing of the second level, the second level being above the first level.

5. The stair system of claim 4, further comprising a supporting beam configured to attach to posts and supporting at least one of a lower landing and an upper landing such that the vertical load from the at least one of a lower landing and an upper landing is transferred via the supporting beam to vertical posts.