Field formable step nose system

Abstract

A step nose is formed having a tread portion and a riser portion, formed initially as a flat strip, the tread portion having a receiving slot formed therein, and the riser portion having a hook formed as part thereof. The tread and riser portions are stretchable with respect to one another so as to enable the hook to interlockingly engage the slot when the tread and riser portions of the flat strip are bent towards one another to thereby form a step nose ready for installation. Machines are further disclosed for forming the flat step nose strip into an assembled state by bending the tread and riser portions and interlocking them together.

1 . Step nose system apparatus comprising:
 a step nose strip having a tread portion and a riser portion;   the tread portion having a receiving slot formed therein; and   the riser portion having a hook formed as part thereof, the tread and riser portions being bendable and stretchable with respect to one another so as to enable the hook to interlockingly engage the slot.   
     
     
         2 . The apparatus of  claim 1  wherein the hook is formed at an interior end of the riser portion, while a hook receiving slot is formed on an interior end of the tread portion, the slot being defined by a projecting lip having an inner surface which projects upwardly at an angle to the horizontal. 
     
     
         3 . The apparatus of  claim 1  further comprising an end cap, and a barbed harpoon connector for attaching the end cap to the step nose strip. 
     
     
         4 . The apparatus of  claim 3  wherein said harpoon connector is inserted in respective oppositely disposed openings in the end cap and the step nose strip. 
     
     
         5 . The apparatus of  claim 1  further comprising a machine for forming the step nose strip into an assembled state. 
     
     
         6 . The apparatus of  claim 5  wherein said machine comprises:
 a first roller and a plurality of cooperating guides for initially bending the step nose strip;   a wheel having a circular flange therein and positioned to cooperate with the first roller to stretch the riser portion of the step nose downwardly and inwardly; and   a mechanical element positioned opposite said circular flange to push the hook portion of said riser portion into said slot.   
     
     
         7 . The apparatus of  claim 6  wherein said element comprises a roller. 
     
     
         8 . The apparatus of  claim 6  wherein said element comprises a mandrel. 
     
     
         9 . The apparatus of  claim 1  further including a flexible web interconnecting said tread portion and said riser portion. 
     
     
         10 . The apparatus of  claim 9  wherein said tread portion comprises a central rectangular opening and first and second rectangular openings disposed adjacent to and on opposite sides of said central rectangular opening, each of the three rectangular openings extending through the length of the step nose strip. 
     
     
         11 . The apparatus of  claim 10  wherein said riser portion comprises first and second rectangular openings disposed adjacent one another and each extending through the length of the step nose strip. 
     
     
         12 . The apparatus of  claim 4  wherein the harpoon connector has a plurality of barbs on opposite edges thereof and wherein the distance from a tip of one barb on one edge to the tip of a barb on the opposite edge is slightly greater than the width of the respective end cap and step nose-openings into which the harpoon connector is to be inserted and wherein the tips of the barbs bend backwards upon insertion to enable insertion of the connector into the respective openings and thereafter “bite” into the respective end cap and step nose openings. 
     
     
         13 . The apparatus of  claim 1  wherein, after interlocking, the tread and riser portions are disposed at angle of less than ninety degrees with respect to one another. 
     
     
         14 . Step nose system apparatus comprising:
 a step nose strip having a tread portion and a riser portion;   the tread portion having a receiving slot formed therein; and   the riser portion having a hook formed as part thereof, the hook and slot being shaped and dimensioned such that the hook may be forced into mating relation with the slot when the tread and riser portions are bent towards one another.   
     
     
         15 . The apparatus of  claim 1  wherein the hook is formed at an interior end of the riser portion, while a hook receiving slot is formed on an interior end of the tread portion, the slot being defined by a projecting lip having an inner surface which projects upwardly at an angle to the horizontal. 
     
     
         16 . The apparatus of  claim 12  wherein, after interlocking, the tread and riser portions are disposed at angle of less than ninety degrees with respect to one another. 
     
     
         17 . The apparatus of  claim 12  further comprising an end cap, and a barbed harpoon connector for attaching the end cap to the step nose strip. 
     
     
         18 . The apparatus of  claim 1  wherein said harpoon connector is inserted in respective oppositely disposed openings in the end cap and the step nose strip. 
     
     
         19 . The apparatus of  claim 1  further comprising a machine for forming the step nose strip into an assembled state. 
     
     
         20 . The apparatus of  claim 5  wherein said machine comprises:
 a first roller and a plurality of cooperating guides for initially bending the step nose strip;   a wheel having a circular flange therein and positioned to cooperate with the first roller to stretch the riser portion of the step nose downwardly and inwardly; and   a roller positioned to push the hook portion of said riser portion into said slot.   
     
     
         21 . A machine for forming a step nose strip into a bent installable form wherein the step nose strip has a riser portion with a hook formed as a part thereof and a tread portion having a receiving slot formed therein, the machine comprising:
 a first roller and a plurality of cooperating guides for initially bending the step nose strip;   a wheel having a circular flange thereon and positioned to cooperate with the first roller to stretch the riser portion of the step nose downwardly and inwardly; and   a mechanical element providing a surface disposed opposite said circular flange, said surface cooperating with said flange to cause interlocking of said hook with said slot   
     
     
         22 . The machine of  claim 20  wherein said element comprises a roller. 
     
     
         23 . The machine of  claim 20  wherein said element comprises a mandrel. 
     
     
         24 . The machine of  claim 22  wherein said surface is conically shaped. 
     
     
         25 . Step nose system apparatus comprising:
 a step nose strip having a tread portion and a riser portion;   an end cap; and   a barbed harpoon connector for attaching the end cap to the step nose strip.   
     
     
         26 . The apparatus of  claim 25  wherein said harpoon connector is inserted in respective oppositely disposed openings in the end cap and the step nose strip. 
     
     
         27 . The apparatus of  claim 26  wherein the harpoon connector has a plurality of barbs on opposite edges thereof and wherein the distance from a tip of one barb on one edge to the tip of a barb on the opposite edge is slightly greater than the width of the respective end cap and step nose-openings into which the harpoon connector is to be inserted and wherein the tips of the barbs bend backwards up on insertion to enable insertion of the connector into the respective openings and thereafter “bite” into the respective openings. 
     
     
         28 . The apparatus of  claim 2  further including a flexible web interconnecting said tread portion and said riser portion. 
     
     
         29 . The apparatus of  claim 28  wherein said tread portion comprises a central rectangular opening and first and second rectangular openings disposed adjacent to and on opposite sides of said central rectangular opening, each of the three rectangular openings extending through the length of the step nose strip. 
     
     
         30 . The apparatus of  claim 29  wherein said riser portion comprises first and second rectangular openings disposed adjacent one another and each extending through the length of the step nose strip.