US20180347205A1

US20180347205A1 - Stair Tread Cover

Info

Publication number: US20180347205A1
Application number: US15/995,435
Authority: US
Inventors: Melissa Rus
Original assignee: Garland Industries Inc
Current assignee: Garland Industries Inc
Priority date: 2017-06-01
Filing date: 2018-06-01
Publication date: 2018-12-06
Also published as: CA3006892A1; CA3006892C; CA3248616A1

Abstract

A stair tread cover suitable for covering at least one step in a staircase. The stair tread cover includes at least a front portion and a back portion. The front and back portion each have a top surface and a bottom surface. At least one adhesive strip is optionally positioned on the bottom surface of the front portion of the stair tread cover, and at least one grip strip is optionally positioned on the top surface of the front portion of the stair tread cover.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Nos. 62/513,682, filed Jun. 1, 2017, the disclosure of which is herein incorporated by reference in its entirety.

BACKGROUND

The present disclosure relates generally to protective coverings, and more particularly to a stair tread cover for protecting stairs and other surfaces during construction, moving, painting, or other activities, and a method of manufacturing the stair tread cover.
The process of building out an area or constructing a building occurs in many phases. During this process, a number of different types of workers are required to complete the construction in stages. As a result, contractors frequently damage stairs, floors, countertops, and other finished work in the process of completing other tasks and moving in and out heavy equipment.
During the last stages of house or building construction, and after the floor and edging materials already have been installed, finish work such as painting, caulking, finish carpentry, and appliance and lighting fixture installation is typically done. This finish work can often cause significant damage to plastic laminates, linoleum, hardwood, ceramic tiles, and carpets before the building is finished, sold, or moved into. Heavy tools, caulking and paint buckets, and appliance edges are particularly damaging, especially when moved up or down stairs.
Traditionally, the only protection, if any, given to floors and/or steps during the final stages of construction has been a thin fabric drop cloth or a thin plastic sheet such as the 0.002-inch-thick self-adhesive plastic sheet. These materials help protect against minimal paint or caulking splatters and soil on workers' feet, however, such materials do not protect against more severe gouges, scrapes, abrasion, or other damage and breakage due to impact of objects or moving of equipment/tools. Additionally, fabric throw rugs or moving van style blankets can be used, but these absorb liquids, snag and catch on appliances, and do not protect against sharp and forceful impact. Also, these covers are bulky and heavy to transport and store and can move or slip on a stair surface, thus potentially creating problems during use.
During construction, painting or other activities, it is often desirable to protect stairs by using surface protectors. However, in instances where a drop cloth or plastic sheet becomes unusable such as, for example, from tearing or from shifting off of or away from the desired stair area, the drop cloth or plastic sheet must be removed, replaced or repositioned, costing the contractor(s) time.
In many cases, especially when construction involves walking or carrying equipment or supplies up and down steps, drop cloths or plastic sheets are not always sufficient in protecting the stairs, particularly when the stairs are finished or carpeted. For example, the size and shape of most drop cloths are often larger than the area to be covered, and are therefore also difficult to clean. Additionally, the removal of drop cloths or plastic sheets often results in the unintentional spreading of dirt, debris or paint back onto the stair surfaces that the covering was designed to protect.
Furthermore, drop cloths are not only bulky and difficult to install, but are also prone to folding, slipping on the stair surface, creasing or bunching, and forming a tripping hazard to contractors.
Non-limiting examples of existing prior art protective surface covers are described in U.S. Pat. No. 6,640,501, and United States Patent Application Nos. US 2008/0066389 and US 2011/0135869, which are incorporated herein.
In view of the current state of protective coverings, there is a need for a protective covering which is adaptable to stairs, which is easy to use, protects a stair surface against sharp and forceful impact, protects the exposed edges of stairs, and which can be easily and conveniently fitted to existing and/or future stairs such that the stairs can still be used while covered with the protective covering.

BRIEF DESCRIPTION

The present disclosure relates to a stair tread cover for protecting stairs and other surfaces during construction, moving, painting, or other activities, and a method of manufacturing the stair tread cover. A stair tread is generally configured to cover at least one step in a staircase. The stair tread cover includes at least a front portion and a back portion. The front and back portion each have a top surface and a bottom surface. At least one adhesive strip can be positioned on the bottom surface of the front portion of the stair tread cover, and at least one grip strip can be positioned on the top surface of the front portion of the stair tread cover.
In another and/or alternative non-limiting aspect of the disclosure, the front portion of the stair tread cover is positionable on the step to protect the stair tread and the back portion is positionable on the step to protect a stair riser of the step in the staircase.
In another and/or alternative non-limiting aspect of the disclosure, the stair tread cover can include a first sheet of material that includes the front portion and a second sheet of material that includes the back portion, wherein the first and second sheets of material are connected together.
In another and/or alternative non-limiting aspect of the disclosure, the stair tread cover can include at least one reinforcement strip positioned on the top surface of the stair tread cover.
In another and/or alternative non-limiting aspect of the disclosure, the front portion of the stair tread cover includes a top panel configured to protect the stair tread and a front panel configured to protect a stair nosing of the step. The back portion can include a vertical panel configured to protect a stair riser of the step. In addition, at least one recess can be included on the top surface of the front portion. The recess, when used, is adapted to receive the at least one grip strip. Moreover, at least one recess can also be included on the bottom surface of the front portion that is adapted to receive at least one adhesive strip.
In another and/or alternative non-limiting aspect of the disclosure, the front portion of the stair tread cover includes at least one portion of an increased thickness. The at least one portion of increased thickness can be formed from one or more layers.
In another and/or alternative non-limiting aspect of the disclosure, there can be provided a set of stair tread covers that can be suitable for covering a plurality of the steps in a staircase.
In another and/or alternative non-limiting aspect of the disclosure, there is provided a method of forming a stair tread cover suitable for covering at least one step in a staircase. The method includes: a) providing at least one sheet of material having a perimeter; and, b) machine-forming the at least one sheet of material into a front portion and a back portion.
In another and/or alternative non-limiting aspect of the disclosure, there is provided a method of: (i) positioning the front portion on the step to protect a stair tread of the step in the staircase, and (ii) positioning the back portion to protect a stair riser of the step in the staircase.
In another and/or alternative non-limiting aspect of the disclosure, there is provided a method of: (a) providing a first sheet of material having a perimeter, (b) machine-forming the first sheet of material into the front portion, (c) providing a second sheet of material having a perimeter, (d) machine-forming the second sheet of material into the back portion, and, (e) connecting the second sheet of material to the first sheet of material. The front portion is positionable on the step to protect a stair tread of the step in the staircase and the back portion is positionable on the step to protect a stair riser of the step in the staircase.
In another and/or alternative non-limiting aspect of the disclosure, the method of machine-forming the first sheet of material further includes the steps of: (1) scoring the first sheet of material to form at least one crease aligned generally parallel to an edge of the perimeter of the first sheet of material; and, (2) folding the first sheet of material along the at least one crease to form a first panel and a second panel on either side of and foldably connected along the at least one crease.
In another and/or alternative non-limiting aspect of the disclosure, the step of machine-forming the first sheet of material further includes the step of impressing the first sheet of material to form a recessed zone on the top surface of the first sheet of material. Additionally, the step of machine-forming the second sheet of material can further include the steps of: i) scoring the second sheet of material to form at least one crease aligned generally parallel to an edge of the perimeter of the second sheet of material; and, ii) folding the second sheet of material along the at least one crease to form a first panel and a second panel on either side of and foldably connected along the at least one crease.
In another and/or alternative non-limiting aspect of the disclosure, the method can further include the steps of: i) applying an adhesive strip to a bottom surface of the front portion of the stair tread cover; and, ii) applying a grip strip to a top surface of the front portion of the stair tread cover.
In another and/or alternative non-limiting aspect of the disclosure, there is provided a stair tread cover suitable for covering at least one step in a staircase. The step includes at least a stair tread and the stair tread cover includes a front portion comprising a first sheet of material having a perimeter, a top surface and a bottom surface; a back portion connectable to the front portion, the back portion comprising a second sheet of material having a perimeter, a top surface and a bottom surface; at least one adhesive strip positioned on the bottom surface of the front portion of the stair tread cover; and, at least one grip strip positioned on the top surface of the front portion of the stair tread cover. The first and second sheets of material are connected to one another. In addition, at least one reinforcement strip can be positioned on the top surface of the front portion of the stair tread cover.
In one non-limiting object of the present disclosure, there is provided a stair tread cover suitable for covering at least one step in a staircase, wherein the step includes at least a stair tread, and the stair tread cover includes a front portion and a back portion, the front and back portion each comprising a top surface and a bottom surface.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover that includes at least one adhesive strip positioned on the bottom surface of the front portion of the stair tread cover.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover that includes at least one grip strip positioned on the top surface of the front portion of the stair tread cover.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover wherein the front portion is positionable on the step to protect the stair tread and the back portion is positionable on the step to protect a stair riser of the step in the staircase.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover wherein the stair tread cover comprises a first sheet of material that includes the front portion and a second sheet of material that includes the back portion, the first and second sheets of material being connected together.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover that includes at least one reinforcement strip positioned on the top surface of the stair tread cover.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover wherein the front portion comprises a top panel configured to protect the stair tread and a front panel configured to protect a stair nosing of the step.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover wherein the back portion comprises a vertical panel configured to protect a stair riser of the step.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover that includes at least one recess on the top surface of the front portion adapted to receive the at least one grip strip.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover that includes at least one recess on the bottom surface of the front portion adapted to receive the at least one adhesive strip.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover wherein the front portion of the stair tread cover comprises at least one portion of an increased thickness.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover wherein the at least one portion of increased thickness is formed from one or more layers.
In another and/or alternative non-limiting object of the present disclosure, there is provided a plurality of stair tread covers suitable for covering a plurality of steps in a staircase.
In another and/or alternative non-limiting object of the present disclosure, there is provided a method of forming a stair tread cover suitable for covering at least one step in a staircase comprising a) providing at least one sheet of material having a perimeter, and b) machine-forming the at least one sheet of material into a front portion and a back portion.
In another and/or alternative non-limiting object of the present disclosure, there is provided a method that includes the steps of: c) positioning the front portion on the step to protect a stair tread of the step in the staircase, and d) positioning the back portion to protect a stair riser of the step in the staircase.
In another and/or alternative non-limiting object of the present disclosure, there is provided a method that comprises providing a first sheet of material having a perimeter; machine-forming the first sheet of material into the front portion; providing a second sheet of material having a perimeter; machine-forming the second sheet of material into the back portion; and, connecting the second sheet of material to the first sheet of material, and wherein the front portion is positionable on the step to protect a stair tread of the step in the staircase and the back portion is positionable on the step to protect a stair riser of the step in the staircase.
In another and/or alternative non-limiting object of the present disclosure, there is provided a method of scoring the first sheet of material to form at least one crease aligned generally parallel to an edge of the perimeter of the first sheet of material, and folding the first sheet of material along the at least one crease to form a first panel and a second panel on either side of and foldably connected along the at least one crease.
In another and/or alternative non-limiting object of the present disclosure, there is provided a method of impressing the first sheet of material to form a recessed zone on the top surface of the first sheet of material.
In another and/or alternative non-limiting object of the present disclosure, there is provided a method of scoring the second sheet of material to form at least one crease aligned generally parallel to an edge of the perimeter of the second sheet of material, and folding the second sheet of material along the at least one crease to form a first panel and a second panel on either side of and foldably connected along the at least one crease.
In another and/or alternative non-limiting object of the present disclosure, there is provided a method of applying an adhesive strip to a bottom surface of the front portion of the stair tread cover, and applying a grip strip to a top surface of the front portion of the stair tread cover.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover suitable for covering at least one step in a staircase, the step including at least a stair tread, the stair tread cover comprising a front portion comprising a first sheet of material having a perimeter, a top surface and a bottom surface; a back portion connectable to the front portion, the back portion comprising a second sheet of material having a perimeter, a top surface and a bottom surface; at least one adhesive strip positioned on the bottom surface of the front portion of the stair tread cover; and at least one grip strip positioned on the top surface of the front portion of the stair tread cover, and wherein the first and second sheets of material are connected to one another.
In another and/or alternative non-limiting object of the present disclosure, there is provided a stair tread cover that includes at least one reinforcement strip positioned on the top surface of the front portion of the stair tread cover.
These and other objects and advantages will become apparent to those skilled in the art upon reading and following the description taken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference may now be made to the drawings which illustrate various non-limiting embodiments that the disclosure may take in physical form and in certain parts and arrangement of parts wherein:

FIG. 1 is an illustration according to one non-limiting embodiment of the present disclosure showing a perspective view of an exemplary stair tread cover made from a single piece of material;

FIG. 2 is an illustration showing additional features of the stair tread cover of FIG. 1 in accordance with the present disclosure;

FIG. 3 is an illustration showing additional features of the stair tread cover of FIG. 1 in accordance with the present disclosure;

FIG. 4 is an illustration showing additional features of the stair tread cover of FIG. 1 in accordance with the present disclosure;

FIG. 5 is an illustration showing additional features of the stair tread cover of FIG. 1 in accordance with the present disclosure;

FIG. 6 is an illustration showing additional features of the stair tread cover of FIG. 1 in accordance with the present disclosure;

FIG. 7 is an illustration showing additional features of the stair tread cover of FIG. 1 in accordance with the present disclosure;

FIGS. 8A-8C illustrate additional features of the stair tread cover of FIG. 1 in accordance with the present disclosure;

FIG. 9 is an illustration according to another non-limiting embodiment of the present disclosure showing a perspective view of an exemplary stair tread cover made from two or more pieces of material;

FIG. 10 is an illustration showing a side view of the stair tread cover of FIG. 9 in accordance with the present disclosure;

FIG. 11 is an illustration according to another non-limiting embodiment of the present disclosure showing a perspective view of another exemplary stair tread cover made from two or more pieces of material, where the two or more pieces of material are in a non-attached configuration;

FIGS. 12A and 12B illustrate additional features of the stair tread cover of FIG. 11 in accordance with the present disclosure;

FIG. 13 is an illustration showing additional features of the stair tread cover of FIG. 11 in accordance with the present disclosure, where the two or more pieces of material are in an attached configuration;

FIG. 14 is an illustration showing additional features of the stair tread cover of FIG. 13 in accordance with the present disclosure;

FIG. 15 is an illustration showing additional features of the stair tread cover of FIG. 13 in accordance with the present disclosure;

FIG. 16 is an illustration showing additional features of the stair tread cover of FIG. 13 in accordance with the present disclosure;

FIGS. 17A-17B illustrate additional features of the stair tread covers of FIGS. 1, 9, and 11 in accordance with the present disclosure, wherein a plurality of stair tread covers are shown; and,

FIG. 18 is an illustration showing additional features of the stair tread covers of FIGS. 1, 9, and 11 in accordance with the present disclosure.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

Referring now to the drawings, wherein the showings are for the purpose of illustrating various non-limiting embodiments of the disclosure only and not for the purpose of limiting the same, the present disclosure provides a system and method for surface protection comprising a stair tread cover that provides protection to stairs and/or stair surfaces.
Referring now to FIGS. 1-18, the present disclosure is directed to a stair or step cover suitable for covering at least one step in a staircase. In traditional staircases, each step in the staircase may include a stair tread (i.e., a top and/or horizontal surface of the step) and a stair riser (i.e., a vertical face of the step). Furthermore, each step in the staircase may include a stair nosing (i.e., an edge of the stair tread extending beyond the front face of a stair riser).
In one non-limiting aspect of the present disclosure, there is provided a stair tread cover comprising one or more body portions 102 including a front portion 104 and a back portion 106. The front and back portions of the stair tread cover can be formed of a single piece of material, as shown in the stair tread cover embodiment 100 illustrated in FIGS. 1-8, or formed from separate pieces of material, as shown in the stair tread cover embodiments 200, 300 illustrated in FIGS. 9-16. Additionally, in such embodiments where separate pieces of material are used, the front and back portions of the stair tread cover can be releasably connected together during use.
In one non-limiting configuration, the front portion 104 of the stair tread covers 100, 200, and 300 described herein are optionally configured to at least partially cover 1) the stair top surface, and/or 2) the stair nosing. In another and/or alternative non-limiting configuration, the back portion 106 of the stair tread covers 100, 200, and 300 described herein are optionally configured to at least partially cover the stair riser. In other words, the body 102 of the stair tread covers 100, 200, and 300 described herein generally includes a first panel 108 that covers a top surface of a stair tread, a second panel 110 that covers the stair nosing, and a third panel 112 that covers the stair riser. In another and/or alternative non-limiting configuration, the front and/or back portions 104, 106 of the stair tread covers 100, 200, and 300 described herein can be sized larger than the stair tread and/or stair riser, respectively, so as to also cover any unprotected part of the adjacent stair riser and/or tread. As such, the presently described stair tread covers 100, 200, and 300 may optionally be configured to cover two, three, or more steps in a staircase.
The material used to form the stair tread cover is non-limiting. The stair tread cover can be formed from one, two, or more different materials. In one non-limiting configuration, the front portion 104 the stair tread covers 200 and 300 of the present disclosure is formed from a first sheet of material having a perimeter and the second portion 106 is formed from a second sheet of material having a perimeter.
In another and/or alternative non-limiting configuration, the material used to form the presently described stair tread covers 100, 200, and 300 can be formed from water-resistant and/or liquid-proof materials. As such, in the instance a fluid (e.g., water, paint, etc.) is spilled on the stair tread cover, the material of the stair tread cover is sufficiently thick and/or sufficiently fluid-impermeable so as to inhibit or prevent the spilled fluid from seeping therethrough and contacting the stairs. In one specific non-limiting configuration, exemplary stair tread covers 100, 200, and 300 can include the use of fiberboard. In another and/or alternative specific non-limiting configuration, presently described stair tread covers 100, 200, and 300 can include the use of paper pulp-based material. In yet another and/or alternative specific non-limiting configuration, exemplary stair tread covers 100, 200, and 300 can include the use of press board material. As defined herein, fiberboard is a type of engineered wood product that is made out of wood fibers. The general types of fiberboard (in order of increasing density) include particle board, medium-density fiberboard, and hardboard. Plywood is not a type of fiberboard, as it is made of thin sheets of wood, not wood fibers or particles. Cardboard is also not fiberboard since it includes a corrugated layer.
In another and/or alternative non-limiting aspect of the present disclosure, the front portion 104 of the stair tread covers 100, 200, and 300 includes a first crease 122. In one non-limiting configuration, the front portion 104 of the stair tread cover is folded along the first crease 122 so as to provide the first or top panel 108 and the second or front panel 110 on either side of the first crease. In one specific non-limiting configuration, the front portion 104 of the stair tread covers 100, 200, and 300 is folded along the first crease 122 such that the first or front panel 108 is substantially perpendicular (e.g., 85-95°) to the second or top panel 110. As such, the second or top panel 110 of the front portion 104 of the stair tread covers 100, 200, and 300 can optionally be bent, folded and/or shaped around a stair nosing. The front portion 104 of the stair tread covers 100, 200, and 300 can optionally be manufactured as a pre-formed component. The type of machine and/or technique used to pre-form (when used) the front portion of the stair tread cover is non-limiting. For example, the front portion of the stair tread cover can optionally be formed via thermo-fitting. The size and shape of the top panel and front panel are non-limiting. In one non-limiting configuration, the second or front panel 110 (i.e., the panel which protects the stair nosing) is about 0.5-6 inches (and all values and ranges therebetween).
In another and/or alternative non-limiting aspect of the present disclosure, the front portion 104 of the stair tread covers 100, 200, and 300 optionally includes one or more areas 124 for at least one adhesive strip 126. The area 124 for the at least one adhesive strip 126 is located on a bottom surface 116 of the stair tread covers 100, 200, and 300. The area 124 for the at least one adhesive strip can be recessed; however, this is not required. If area 124 is recessed, the recess is generally less than the thickness of the adhesive tape. In one non-limiting configuration, the at least one adhesive strip 126 (when used) is a rubber-like material. In another and/or alternative non-limiting configuration, the at least one adhesive strip 126 is a carpet tape. In another and/or alternative non-limiting configuration, the at least one adhesive strip 126 is positioned on the bottom surface 116 of the first or top panel 108 of the front portion 104 of the stair tread covers 100, 200, and 300. The at least one adhesive strip 126 (when used) provides a temporary, non-slip contact between the top surface of a stair surface and the bottom surface 116 of the exemplary stair tread covers. Furthermore, the at least one adhesive strip 126 allows the stair tread covers to be usable on various types of surfaces including, but not limited to, hardwood surfaces, laminate surfaces, carpeted surfaces, non-carpeted surfaces, concrete surfaces, composite surfaces, plastic surfaces, plywood surfaces, etc. The temporary adhesive bond can optionally form a dust-proof, dirt-proof and/or liquid-proof bond between the stair tread covers and the underlying stair. As such, during use, dirt and/or debris can be prevented from working its way under the presently described stair tread covers and between the stair tread covers and the stair. The temporary adhesive strip can be a pre-applied adhesive strip. The at least one adhesive strip can optionally include a corresponding removable protective release liner 128 (FIG. 18) that, when removed, exposes an adhesive surface of the adhesive strip. The exposed adhesive surface of the adhesive strip is designed to form a temporary (i.e., removable) bond with a top surface of a stair and the stair tread cover. The temporary, adhesive bond between the exposed adhesive surface and the stair is designed to sufficiently hold the stair tread cover in position and prevent the stair tread cover from sliding or moving relative to the stair, while still remaining removable such that the stair tread cover can be removed from the stair before, during, or after use without damage to the stair.
The size, shape and quantity of the at least one adhesive strip 126 is non-limiting. Generally, the width of the adhesive strip is 0.25-5 inches and all values and ranges therebetween (e.g., 1 inch, 2 inches, 2.5 inches, etc.). The thickness of the adhesive strip is generally less than 0.25 inches (e.g., 0.004-0.24 inches and all values and ranges therebetween), and typically about 0.004-0.15 inches. In one non-limiting configuration, at least one adhesive strip 126 is generally positioned parallel at or near the first fold 122 in the front portion 104 of the presently described stair tread covers to provide a non-slip surface at or near the step nosing (the most frequently contacted part of the step). As can be appreciated, one or more additional adhesive strips can be positioned adjacent to the adhesive strip 126 of the stair tread cover. When two of more adhesive strips are used, such adhesive strips are generally spaced from one another; however, this is not required. As can also be appreciated, the stair tread cover can optionally include adhesive strips positioned on other surfaces (i.e., the second or front panel 110 of the front portion 104 of the stair tread covers) to correspond to other portions of steps (e.g., stair nosing, etc.) which may be in contact with a user or equipment. For example, as shown in FIG. 14, adhesive strips may be positioned parallel at or near the first fold at surface 136 a and/or perpendicular to the first fold at or near the sides 136 b, 136 c of the stair tread covers. In another and/or alternative non-limiting configuration, at least one adhesive strip 126 is optionally generally positioned at or within 1-2 inches of the front of the stair tread cover. In another and/or alternative non-limiting configuration, at least one adhesive strip 126 is optionally generally positioned at or near perimeter surfaces 136 a, 136 b, 136 c (FIG. 14) of the stair tread cover. The number and orientation of the one or more adhesive strips on the bottom surface 116 of the presently described stair tread covers 100, 200, 300 is non-limiting. As illustrated in FIG. 7, the adhesive strip 126 is positioned generally parallel to the front edge of the front portion 104. The adhesive strip 126 is also illustrated as extending the full width of the front panel 110. Generally, the adhesive strip 126 is configured to extend at least 50% the width of the front panel 110, and typically extend at least 70% the width of the front panel 110. If more than one adhesive strip 126 is used and positioned along the generally same plane along the width of the front panel 110, the total length of the plurality of adhesive strips are configured to extend at least 50% the width of the front panel 110, and typically extend at least 70% the width of the front panel 110.
In another and/or alternative non-limiting aspect of the present disclosure, the front portion 104 of the stair tread covers 100, 200, 300 on a top surface 114 of the stair tread cover optionally includes one or more areas 130 for at least one grip strip 132 to be positioned. In one non-limiting configuration, the grip strip is a sandpaper-like material. In another and/or alternative non-limiting configuration, the at least one grip strip 132 is a grip tape. In another and/or alternative non-limiting configuration, at least one grip strip 132 is positioned on the top surface 114 of the first or top panel 108 of the front portion 104 of the stair tread covers 100, 200, 300. Optionally, as shown in FIGS. 8A-8C, the top surface 114 of the first or top panel 108 of the front portion 104 can include one or more recesses 134 into which the at least one grip strip 132 may be placed. In such a configuration, the thickness of the grip strip 132 is greater than the thickness of the recess 134 in the front portion 104 such that the grip strip extends upwardly from the top surface 114 of the front portion. The at least one grip strip 132 (when used) provides a non-slip contact on the top surface 114 of the stair tread covers 100, 200, 300 so as to improve the traction and/or grip between a user's shoe and the stair tread cover. As such, during use, injury as a result of a person or equipment sliding on the stair tread cover can be reduced or prevented. The at least one grip strip 132 can be a pre-applied grip strip. The at least one grip strip can optionally include a removable protective release liner (not shown) that, when removed, exposes a top surface of the at least one grip strip. In one specific non-limiting configuration, the at least one grip strip 132 is a formed of grip tape applied to a recess 134 on the top surface 114 of the front portion 104 of the exemplary stair tread covers 100, 200, 300. In another specific non-limiting configuration, as shown in FIGS. 2, 4, and 5, for example, the at least one grip strip 132 is a formed of grip tape applied to the top surface 114 of the front portion 104 of the stair tread cover 100.
The size, shape and quantity of the at least one grip strip 132 is non-limiting. Generally, the width of the grip strip is about 0.25-5 inches and all values and ranges therebetween (e.g., 1 inch, 2 inches, 2.5 inches, etc.). The thickness of the grip strip is generally less than 0.25 inches (e.g., 0.004-0.24 inches and all values and ranges therebetween), and typically 0.005-0.18 inches. In one non-limiting configuration, a first grip strip 132 is generally positioned parallel at or near the first fold 122 in the stair tread cover to provide a non-slip surface at or near the step nosing (the most frequently contacted part of the step). As can be appreciated, one or more additional grip strips can be positioned adjacent to the first grip strip of the stair tread cover. As can be appreciated, the stair tread cover can include additional grip strips positioned to correspond to other portions of steps which may be in contact with a user or equipment (e.g., stair risers, stair nosing, etc.). In another and/or alternative non-limiting configuration, a grip strip is optionally generally positioned at or within 0-3 inches (and all values and ranges therebetween) of the front of the stair tread cover, and typically about 1-2 inches of the front of the stair tread cover. In another and/or alternative non-limiting configuration, a grip strip is optionally generally positioned at or near the perimeter of the stair tread cover, such as, for example, locations 134 a, 134 b, and 134 c shown in FIG. 13.
In another and/or alternative non-limiting aspect of the present disclosure, when a first grip strip 132 and a first adhesive 126 are used, the first grip strip is optionally positioned directly above or at least partially overlaps the first adhesive on the top surface 114 of the stair tread covers. In this regard, in another and/or alternative non-limiting aspect of the present disclosure, the grip strip 132 can be optionally provided in the recess 134 on the top surface 114 of the front portion 104 and the adhesive 126 can be optionally provided in its own recess 136 directly beneath the grip strip recess and on the bottom surface 116 of the front portion, as shown in FIGS. 8A-8C. As also shown in FIGS. 8B-8C, which illustrate a zoomed-in view of section A from FIG. 8A, in another and/or alternative non-limiting aspect of the present disclosure, the grip strip and the adhesive can be provided as substantially solid pieces of material 132 a, 126 a, respectively, as particularly shown in FIG. 8B. Alternatively, the grip strip and the adhesive can be provided as one or more pieces of material 132 b, 126 b, respectively, as particularly shown in FIG. 8C. As such, during use, when a user walks on the grip strip on the top surface of the stair tread cover, the weight of the user reinforces/re-engages the temporary bond between the adhesive on the bottom of the stair tread cover and the top surface of the stair tread. In prior art protective coverings which are not bonded to a surface, the protective covering tends to slide or be displaced from its original position. One non-limiting advantage of the stair tread cover of the present disclosure is that, over time, as users repetitively step on the grip strip, the stair tread cover is not displaced from its original position, unless physically removed from the position by a user.
In another and/or alternative non-limiting aspect of the present disclosure, the stair tread covers can also include at least one reinforcement strip positioned on the top surface 114 of the stair tread cover. For example, the front portion 104 of the exemplary stair tread cover 100 optionally includes a reinforcement strip 138 adapted to reinforce an area of high stress and strain. In one non-limiting configuration shown in FIG. 4, the reinforcement strip 138 can be provided at the first crease 122 of the front portion 104 of the stair tread cover. In addition, or alternatively, a reinforcement strip 140 can be provided at the second crease 142 of the back portion 106 of the stair tread cover as shown in FIG. 5. The at least one reinforcement strip 138, 140 (when used) provides a portion of stair tread cover which has significant stability and durability reinforcement. As such, during use, damage to the stair tread cover at or near the nose of the stair can be prevented. The reinforcement strip can be a pre-applied reinforcement strip. The reinforcement strip can thus be used to provide reinforcement and wear resistance to the region about first crease 122. Generally, the reinforcement strip (when used) fully overlies the first crease 122 and typically extends about 0.5-4 inches on each side of the first crease 122. As such, the reinforcement strip (when used) does not typically cover the full top or bottom surface of the stair tread covers 100, 200, and 300. The reinforcement strip (when used) when used, generally extends 70-100% the width of the front panel 110. The reinforcement strip (when used) generally is formed of a fiber, plastic or paper material (e.g., paper tape, fiber-reinforced paper tape, plastic tape, etc.). Generally, the reinforcement strip (when used) is secured to the front panel 110 by an adhesive; however, other means can be used (e.g., melted seam, etc.).
The at least one reinforcement strip 138, 140 can be used for: i) reinforcement of the stair tread cover, and/or ii) retaining the shape of the stair tread cover in a bent and/or biased position. For example, in non-limiting configuration, the stair tread cover includes one or more folds and/or bends wherein each of the folds and/or bends can position a portion of the stair tread cover horizontally and another portion of the stair tread cover vertically such as, for example, around a stair nosing. In such a configuration, when a reinforcement strip is applied at or near the stair nosing, the reinforcement strip can: i) provide improved stability and/or durability at or near the stair nosing, and/or ii) at least partially help retain the bend and/or folded shape of the stair tread cover such that the stair tread cover can fit snugly around the stair nosing. It can be appreciated that the reinforcement strip can have other or alternative uses.
The width and thickness of the at least one reinforcement strip 138, 140 is non-limiting. Generally, the width of the reinforcement strip is 0.25-5 inches and all values and ranges there between (e.g., 1 inch, 2 inches, 2.5 inches, etc.). The thickness of the reinforcement strip is generally less than 0.1 inches (e.g., 0.003-0.05 inches). A first reinforcement strip is generally positioned at or near the first fold 122 in the stair tread cover to provide an area of reinforcement at or near the step nosing (the most frequently contacted part of the step). As can be appreciated, one or more additional reinforcement strips can be positioned adjacent to the first reinforcement strip of the stair tread cover. The stair tread cover can include one, two, or more reinforcement strips. In one non-limiting arrangement, the stair tread cover includes one reinforcement strip positioned on a top surface of the stair tread cover. As can be appreciated, the stair tread cover can include one or more reinforcement strips positioned to correspond to other portions of steps (e.g., stair risers, stair nosing, etc.) which may be in contact with a user or equipment. In another and/or alternative non-limiting configuration, a reinforcement strip is optionally generally positioned at or within 0-2 inches of each fold of the stair tread cover. In another and/or alternative non-limiting configuration, a reinforcement strip is optionally generally positioned at or near the perimeter of the stair tread cover.
In another and/or alternative non-limiting aspect of the present disclosure, the front portion 104 of the presently described stair tread cover optionally includes at least one portion of an increased thickness, such as portion 150 illustrated on the stair tread cover 300 of FIG. 13. The increased thickness portion 150 (when used) can be formed from the application of one or more layers of the first material. Furthermore, the increased thickness portion 150 (when used) may improve the rigidity and durability of the stair tread cover.
In another and/or alternative non-limiting aspect of the present disclosure, the front portion 104 of the stair tread cover optionally includes a plurality of surface projections, such as the plurality of surface projections 152 on the stair tread cover 300 illustrated in FIGS. 11-16, for example. The one or more surface projections 152 (when used) may be provided to at least partially improve traction as a user walks over the stair tread cover. The size, shape, and quantity of surface projections is non-limiting. Thus, when the one or more surface projections 152 are used, a user's traction may be improved.
In another and/or alternative non-limiting aspect of the present disclosure, the back portion 106 of the stair tread covers 100, 200, 300 optionally includes at least one crease 142. The crease 142 (when used) allows the material of the back portion of the stair tread cover to be bent and/or folded along the crease. As can be appreciated, the number of creases is non-limited. The one or more creases can be used to adjust the height of the back portion to fit under different height stairs. In one non-limiting configuration, the back portion 106 of the stair tread covers includes a first crease 142, wherein the first crease is offset a distance inward from the end of the sheet of material. As such, in embodiments where the stair tread cover is made from a single piece of material, such as cover 100 illustrated in FIGS. 1-8, the back portion 106 of the stair tread cover can be folded along the first crease 142 so as to create the first or horizontal top panel 108 and the third or vertical stair riser panel 112 on either side of the first crease. In embodiments where the stair tread cover is made from two or more pieces of material, such as covers 200, 300 illustrated in FIGS. 9-16, the back portion or second piece of material 106 can be folded along the first crease 142 so as to create a first vertical stair riser panel 112 a and a second horizontal stair riser panel 112 b on either side of the first crease.
In such embodiments where the stair tread cover is made from two or more pieces of material, the second horizontal stair riser panel 112 b of the back portion 106 of the stair tread cover may be provided to: 1) protect a portion of the top tread surface of the step, and/or 2) provide a connection to the front portion 104 of the stair tread cover. Similarly, the first vertical stair riser panel 112 a of the back portion 106 of the stair tread cover may be provided to protect the stair riser of a step. In one non-limiting configuration, the horizontal panel 112 b is generally perpendicular (e.g., 85-95°) to the vertical panel 112 a during use of the stair tread cover on a stair.
In any of the exemplary embodiments described herein, the crease 142 can be located on either the top 114 or bottom surface 116 of the back portion 106 of the stair tread covers. The crease 142 generally includes a respective offset from an end of the sheet of material. In one non-limiting arrangement, the first crease 142 is parallel to one end of the sheet of material. The crease can optionally be perforated and/or water resistant. In another non-limiting configuration, the back portion 106 of the stair tread cover optionally includes an additional area 144 for additional creases 146, as shown on the cover 100 illustrated in FIGS. 3 and 4. Based on the depth of a particular stair, the stair tread cover can be bent at the crease (i.e., crease 142 or one of the additional creases 146) that provides a depth of the stair tread cover that best matches the depth of the stair.
A creasing wheel can optionally be used to form the one or more creases in the material of the stair tread cover. The scoring in the material includes a depth from about 5% to about 30% of a depth of the sheet of material, typically about 10% to 20% of a depth of the sheet of material. In one non-limiting arrangement, the scoring in the sheet of material includes a depth from about 14.5% of the sheet material. Generally, the depth of the crease is constant along the length of the crease.
The term ‘crease’ as used herein includes scoring or perforating the surface of the sheet of material. As such, the presently described stair tread covers 100, 200, 300 can provide simultaneous horizontal (i.e. stair tread, stair nosing) and vertical (i.e. stair riser, stair nosing) protection within a single product. The crease (when used) is generally positioned 0.5 to 12 inches (and all values and ranges therebetween) from a first end of the sheet of material. When the first crease is formed generally parallel to an end of the sheet of material, the crease is generally spaced about 0.5-12 inches from the end of the sheet of material, typically 1-10 inches, more typically about 1.25-8 inches, and still more typically 1.5-6 inches.
In another and/or alternative non-limiting aspect of the present disclosure, the vertical panel 112 of the back portion 106 of the exemplary stair tread covers can optionally include one or more temporary adhesive strips (not shown) applied thereto. The adhesive strip (when used) can be the same or different as the adhesive strip described above with reference to the first portion 104 of the stair tread covers. The one or more adhesive strips (when used) may be provided on the vertical panel 112 of the back portion 106 for the purpose of preventing the vertical portion of the stair tread cover from collapsing over the front portion 104 of the stair tread cover and exposing the stair riser.
During installation, one or more stair tread covers in accordance with the present disclosure can be applied to one or more steps in a staircase. For example, as shown in FIGS. 17A-17B, a plurality of stair tread cover bodies 102 a-102 e can be provided. FIG. 17A illustrates the plurality of stair tread cover bodies 102 a-102 e as an exemplary product package containing multiple stair tread covers as described herein, and FIG. 17B illustrates the plurality of stair tread cover bodies 102 a-102 e being installed to multiple steps in a staircase. Initially, a first stair tread cover, such as cover body 102 a, is positioned on a first step to be covered. After the first stair tread cover is positioned on the first step, a user can simply walk on the top surface of the stair tread cover in the area of the adhesive strip on the stair tread cover to complete the temporary adhesive bonding of the stair tread cover to the stair tread. The vertical portion of the first stair tread cover can be folded upwardly as to be positioned along the stair riser of the first step. This process can then be repeated to secure additional stair tread covers 102 b-102 e to additional steps. For example, second stair tread cover body 102 b can then be positioned on a second step to be covered. After the second stair tread cover body 102 b is positioned on a second step, a user can simply walk on the top surface of the second stair tread cover in the area of the adhesive strip on the second stair tread cover to complete the temporary adhesive bonding of the stair tread cover to the stair tread. The vertical portion of the second stair tread cover can be folded upwardly as to be positioned along the stair riser of the second step.
The use of a pre-applied temporary adhesive strip on the presently described stair tread covers 100, 200, 300 eliminates the need to apply a separate piece of tape or other adhesive over the edge of stair tread cover to secure the stair tread cover to the step. Additionally, using a pre-applied temporary adhesive strip also makes installation of the stair tread cover faster and easier.
One non-limiting advantage of the stair tread covers 100, 200, 300 of the present disclosure is that the stair tread covers offer protection to various parts of stairs within a single product. For example, the stair tread cover of the present disclosure protects the 1) stair tread, the actual step where a user places his/her foot as he/she walks thereon, 2) stair riser, a portion of a stair that is often kicked with a user's toe as the user walks up the stairs, and/or 3) stair nosing, the most often damaged portion of a stair.
In summary, the present disclosure is directed to stair tread covers 100, 200, 300 configured to protect selected portions of surfaces such as, for example, stairs. The stair tread covers can be sized to fit an individual step in a standard flight of stairs; however, the stair tread cover can be configured to accommodate non-standard flights of stairs (e.g. non-linear staircases, spiral staircases, etc.). The stair tread covers can be a non-reusable (i.e. one-time use) surface protector. As can be appreciated, the stair tread covers of the present disclosure can be used multiple times. In one non-limiting configuration, the stair tread covers 100, 200, 300 comprise a front portion and a back portion. The front portion of the stair tread covers can further comprise a first sheet of material having a perimeter, a top surface and a bottom surface. Similarly, the back portion of the stair tread cover can further comprise a second sheet of material having a perimeter, a top surface and a bottom surface. As can be appreciated, the stair tread covers can also be formed of a single sheet of material. The stair tread covers include at least one adhesive strip and at least one grip strip. The adhesive strip(s) are generally positioned on a first surface of the first sheet material so as to correspond to a stair tread. Likewise, the grip strip(s) are generally positioned on a second surface of the first sheet of material so as to correspond with a surface on which a user walks. The number of adhesive strips and/or grip strips may vary slightly due to the users' custom needs. The back portion of the stair tread cover optionally includes at least one crease, the at least one crease configured to allow the second sheet of material to be bent.
In another and/or alternative non-limiting aspect of the present disclosure, there is provided a method of forming the exemplary stair tread cover 100 described above. The method can comprise the steps of: 1) providing a sheet of material having a perimeter, 2) machine-forming the sheet of material so as to form a first portion of the stair tread cover which complements at least the size and shape of a stair tread of a step in a staircase, 3) machine-forming the sheet of material so as to form the first portion of the stair tread cover having a portion which complements at least the size and shape of a stair nosing of a step in a staircase, and/or 4) machine-forming the sheet of material so as to form a second portion of the stair tread cover which complements at least the size and shape of at least a stair riser of the step in the staircase.
In another and/or alternative non-limiting aspect of the present disclosure, there is provided a method of forming the exemplary stair tread covers 200, 300 described above. The method can comprise the steps of: 1) providing a first sheet of material having a perimeter, 2) machine-forming the first sheet of material so as to form a first portion of the stair tread cover which complements at least the size and shape of a stair tread of a step in a staircase, 3) providing a second sheet of material having a perimeter, 4) machine-forming the second sheet of material so as to form a second portion of the stair tread cover which complements the size and shape of at least a stair riser of the step in the staircase, and/or 5) connecting the second sheet of material to the first sheet of material to form the stair tread cover. The connection between the first and second sheets of material is non-limiting. For example, a non-releasable adhesive may be used to connect the first and second sheets of material.
The step of machine-forming the sheet or the first sheet of material can further optionally include the step of impressing the sheet material to form a recessed zone on the top surface of the sheet material, wherein the recessed zone is suitable for attachment of a grip strip.
The methods described above can also comprise the steps of: a) applying an adhesive strip to a bottom surface of the front portion of the stair tread cover, and/or b) applying a grip strip to a top surface of the front portion of the stair tread cover. The grip strip can be applied within the recessed zone on the top surface of the front portion of the stair tread cover. Optionally, the method can further include the step of applying an adhesive strip to a back surface of the back portion of the stair tread cover to provide a temporary bond between the stair tread cover and a stair riser.
As can be appreciated, the stair tread cover can be formed of a single piece of material that is preformed and cut into shape.
The size of the stair tread cover of the present disclosure is non-limiting. In one non-limiting configuration, the vertical height of the stair tread cover is about 2 inches to about 20 inches, more typically about 3-10 inches, and more typically about 4-8 inches. In one specific non-limiting configuration, the stair tread cover is 6 inches in height. In another and/or alternative non-limiting configuration, the width of the stair tread cover is about 2 inches to about 48 inches, more typically about 4-36 inches, and more typically about 6-24 inches. In one specific non-limiting configuration, the width of the stair tread cover is about 10-11 inches.
One non-limiting object of the present disclosure is the provision of a stair tread cover that provides protection to stairs and/or stair surfaces.
Another and/or alternative non-limiting object of the present disclosure is the provision of a stair tread cover that includes at least one adhesive strip used to connect the stair tread cover to a stair tread.
Yet another and/or alternative non-limiting object of the present disclosure is the provision of a stair tread cover that includes at least one grip strip used to provide a non-slip surface to the stair tread cover.
Still yet another and/or alternative non-limiting object of the present disclosure is the provision of a stair tread cover which includes: 1) at least one adhesive strip, and 2) at least one grip strip.
Another and/or alternative non-limiting object of the present disclosure is the provision of a stair tread cover which includes at least one adhesive strip that is a pre-applied adhesive strip.
Another and/or alternative non-limiting object of the present disclosure is the provision of a method for forming a stair tread cover that provides protection to stairs and/or stair surfaces.
It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Claims

What is claimed:

1. A stair tread cover suitable for covering at least one step in a staircase, the step including at least a stair tread, the stair tread cover comprising:

a front portion and a back portion, the front and back portion each comprising a top surface and a bottom surface;

at least one adhesive strip positioned on the bottom surface of the front portion of the stair tread cover; and,

at least one grip strip positioned on the top surface of the front portion of the stair tread cover.

2. The stair tread cover of claim 1, wherein the front portion is positionable on the step to protect the stair tread and the back portion is positionable on the step to protect a stair riser of the step in the staircase.

3. The stair tread cover of claim 1, wherein the stair tread cover comprises a first sheet of material that includes the front portion and a second sheet of material that includes the back portion, the first and second sheets of material being connected together.

4. The stair tread cover of claim 1, further comprising at least one reinforcement strip positioned on the top surface of the stair tread cover.

5. The stair tread cover of claim 1, wherein the front portion comprises a top panel configured to protect the stair tread and a front panel configured to protect a stair nosing of the step.

6. The stair tread cover of claim 1, wherein the back portion comprises a vertical panel configured to protect a stair riser of the step.

7. The stair tread cover of claim 1, further comprising at least one recess on the top surface of the front portion adapted to receive the at least one grip strip.

8. The stair tread cover of claim 7, further comprising at least one recess on the bottom surface of the front portion adapted to receive the at least one adhesive strip.

9. The stair tread cover of claim 1, wherein the front portion of the stair tread cover comprises at least one portion of an increased thickness.

10. The stair tread cover of claim 9, wherein the at least one portion of increased thickness is formed from one or more layers.

11. The stair tread cover of claim 1, further comprising a plurality of stair tread cover suitable for covering the steps the staircase.

12. A method of forming a stair tread cover suitable for covering at least one step in a staircase, the method comprising:

providing at least one sheet of material having a perimeter; and,

machine-forming the at least one sheet of material into a front portion and a back portion.

13. The method of claim 12, further comprising the steps of

positioning the front portion on the step to protect a stair tread of the step in the staircase, and

positioning the back portion to protect a stair riser of the step in the staircase.

14. The method of claim 12, further comprising:

providing a first sheet of material having a perimeter;

machine-forming the first sheet of material into the front portion;

providing a second sheet of material having a perimeter;

machine-forming the second sheet of material into the back portion; and,

connecting the second sheet of material to the first sheet of material,

wherein the front portion is positionable on the step to protect a stair tread of the step in the staircase and the back portion is positionable on the step to protect a stair riser of the step in the staircase.

15. The method of claim 14, wherein the step of machine-forming the first sheet of material further comprises the steps of:

scoring the first sheet of material to form at least one crease aligned generally parallel to an edge of the perimeter of the first sheet of material; and,

folding the first sheet of material along the at least one crease to form a first panel and a second panel on either side of and foldably connected along the at least one crease.

16. The method of claim 14, wherein the step of machine-forming the first sheet of material further comprises the step of impressing the first sheet of material to form a recessed zone on the top surface of the first sheet of material.

17. The method of claim 14, wherein the step of machine-forming the second sheet of material further comprises the steps of:

scoring the second sheet of material to form at least one crease aligned generally parallel to an edge of the perimeter of the second sheet of material; and,

folding the second sheet of material along the at least one crease to form a first panel and a second panel on either side of and foldably connected along the at least one crease.

18. The method of claim 12, further comprising the steps of:

applying an adhesive strip to a bottom surface of the front portion of the stair tread cover, and,

applying a grip strip to a top surface of the front portion of the stair tread cover.

19. A stair tread cover suitable for covering at least one step in a staircase, the step including at least a stair tread, the stair tread cover comprising:

a front portion comprising a first sheet of material having a perimeter, a top surface and a bottom surface;

a back portion connectable to the front portion, the back portion comprising a second sheet of material having a perimeter, a top surface and a bottom surface;

at least one grip strip positioned on the top surface of the front portion of the stair tread cover,

wherein the first and second sheets of material are connected to one another.

20. The stair tread cover of claim 19, further comprising at least one reinforcement strip positioned on the top surface of the front portion of the stair tread cover.