Stair component, stair edge nose cover and method

Abstract

A stair component has foundation member including a nose end. Upon attachment of the component to a stair, the nose end projects outwardly from an upper forward edge of the stair. The nose end has a substantially uniform cross-sectional configuration along substantially its entire width. A nose cover having an ornamental exterior surface overlies and covers substantially the entire nose end. The nose cover comprises a thin continuous sheet of preformed plastic having first and second substantially parallel planar portions joined by a curved portion. The foundation member, which may be constructed on site or formed off-site, is adapted to be positioned (a) directly next to a riser portion of the stair so that a vertical support element of the foundation member abuts the riser portion or (b) indirectly so that the vertical support element abuts a secondary vertical member disposed between the foundation member and the riser portion.

1 . A stair component for attachment to a stair comprising
 a foundation member having a predetermined width substantially equal to the width of the stair to which the component is to be attached and a pair of legs substantially at a right angle with one of the legs being adapted to be attached to a riser portion of the stair and the other leg terminating in a nose end that projects outwardly from an upper forward edge of the stair upon attaching the foundation member to the stair,   said nose end having a substantially uniform cross-sectional configuration along substantially the entire width of the foundation member and being covered with a thin sheet having an ornamental exterior surface overlying and covering the nose end.   
     
     
         2 . The stair component of  claim 1  where the nose end is rounded and its entire exterior surface is substantially covered. 
     
     
         3 . The stair component of  claim 1  where the foundation member is constructed on a job site. 
     
     
         4 . The stair component of  claim 1  where the foundation member is formed away from a job site and delivered to the job site for installation. 
     
     
         5 . The stair component of  claim 4  where the foundation member comprises an extruded plastic material. 
     
     
         6 . The stair component of  claim 4  where the foundation member comprises a molded plastic material with apertures therein. 
     
     
         7 . A stair component for attachment to a stair comprising
 a foundation member including a nose end that projects outwardly from an upper forward edge of the stair upon attaching the foundation member to the stair,   said nose end being covered with a thin sheet having an ornamental exterior surface overlying and covering the nose end, said nose end being rounded and its entire exterior surface being substantially covered by said thin sheet.   
     
     
         8 . A stair edge nose cover comprising
 a thin continuous sheet of preformed plastic having an ornamental exterior surface and   opposed substantially parallel side edges spaced apart a distance substantially from 30 to 240 inches,   a thickness substantially from ⅛ to ¼ inch,   a first substantially planar portion having a length substantially from 1.5 to 5 inches and terminating in a substantially straight rear edge,   a second substantially planar portion having a length substantially from ⅜ to ¾ inch and terminating in a substantially straight rear edge that is inward of the rear edge of the first planar portion, and   a curved portion joining the first and second planar portions, said curved portion having a radius of curvature of substantially from ¾ to 1.5 inch.   
     
     
         9 . The stair edge nose of  claim 8  where the sheet is preformed by heating and forming a substantially flat sheet of plastic into a bent sheet to provide the curved portion joining the first and second planar portions. 
     
     
         10 . A stair component for attachment to a stair having a predetermined width, a substantially horizontal upper landing, and a riser portion having predetermined height extending from a substantially horizontal lower landing to the upper landing,
 said stair component comprising
 a foundation member adapted to be positioned next to the riser portion and including substantially vertical and horizontal support elements, each element having a predetermined thickness substantially from ½ to 3 inches and a width that is substantially equal to the width of the stair, said support elements being substantially at a right angle to each other and substantially in registration in the width direction, 
   said vertical support element having a front side and a rear side, and a bottom edge,   said horizontal support element includes a forward rounded nose end, a rear end, a topside, and distance from the nose end to the rear end is substantially from 1 to 4.5 inch,   upon positioning the foundation member next to the riser portion, the rear end of the horizontal support element is substantially flush with the rear side of the vertical support element and the forward rounded nose end extends beyond the front side of the vertical support element substantially from ¾ to 1.5 inch,   upon positioning the foundation member next to the riser portion, the vertical support element's front side faces away from the riser portion and the rear side faces toward the riser portion and the bottom edge of the vertical support element is near the lower landing, and the topside of the horizontal support element is substantially flush with the horizontal upper landing,   a first thin sheet having an ornamental exterior surface overlying and covering substantially the entire forward rounded nose end and topside of the horizontal support element, said first thin sheet having a curved forward end that is preformed to fit snugly over the forward rounded nose end of the horizontal support element, and   a second substantially flat thin sheet having an ornamental exterior surface overlying and covering substantially the entire front side of the vertical support element.   
     
     
         11 . The stair component of  claim 10  where a fastening member extends into and though the nose end to hold the stair component in position, said first thin sheet covering any exposed portion of the fastening member. 
     
     
         12 . The stair component of  claim 10  where a secondary vertical support element is disposed between the foundation member and the riser portion of the stair. 
     
     
         13 . The stair component of  claim 10  where the foundation member consists essentially of wood. 
     
     
         14 . The stair component of  claim 10  where the foundation member consists essentially of plastic. 
     
     
         15 . The stair component of  claim 10  where the first thin sheet has an upper portion that is bonded to the topside of the horizontal support element and terminates in a first edge that is inward of the nose end and a lower portion that terminates in a second edge that is inward of the nose end and abuts the front side of the vertical support element. 
     
     
         16 . The stair component of  claim 15  where the first edge is substantially adjacent to the vertical rear end of the horizontal support element or projects inward. 
     
     
         17 . The stair component of  claim 10  where the foundation member is adapted to be positioned next to the riser portion directly so that the vertical support element abuts the riser portion. 
     
     
         18 . The stair component of  claim 10  where the foundation member is adapted to be positioned next to the riser portion indirectly so that the vertical support element abuts a secondary vertical member disposed between the foundation member and the riser portion. 
     
     
         19 . A method of laminating a stair comprising the steps of
 (a) attaching a foundation member to the stair, said foundation member having a nose portion that projects outwardly from an upper forward edge of the stair upon attaching the foundation member to the stair, and   (b) covering with a thin sheet having an ornamental exterior surface substantially the entire nose end.   
     
     
         20 . The method of  claim 19  where the nose portion has a rounded forward surface and extends at least ¾ inch outward from a riser portion of the stair. 
     
     
         21 . The method of  claim 20  where the foundation member is positioned next to the riser portion directly so that a vertical support element of the foundation member abuts the riser portion. 
     
     
         22 . The method of  claim 20  where the foundation member is positioned next to the riser portion indirectly so that a vertical support element of the foundation member abuts a secondary vertical member disposed between the foundation member and the riser portion. 
     
     
         23 . A step comprising
 an upper landing covered with a first laminate sheet having a predetermined an ornamental exterior surface,   said upper landing having a rounded nose portion projecting outward from an upper forward edge of the upper landing to extend beyond a riser portion that is beneath an underside of the upper landing,   said nose portion being covered with a second laminate sheet having essentially the same predetermined ornamental exterior surface as the first sheet.   
     
     
         24 . The step of  claim 23  where the nose portion extends at least ¾ inch outward from the riser portion.