FIELD OF THE INVENTION

The present invention relates generally to the construction of stairs and, more particularly, to a stair tread overlay for installation on the stair steps of an existing stairway construction.

BACKGROUND OF THE INVENTION

It is well known that stair treads may wear out over extended or heavy use. Rather than replacing an entire staircase, or going to the significant expense of removing the existing worn tread to permit complete replacement, it also is known to cover over the treads of a worn staircase with a new material.

In other words, replacing stairs is quite expensive and requires considerable labor because the existing stairs must be removed and a new set of finished stairs put in their place. Removal of the existing staircase not only is expensive, but access to other floors may also be limited in the home during construction.

In other applications, existing stair steps may be covered with carpeting over plain lumber. If it is desired to remove the carpeting and provide more aesthetically pleasing wood surfaces, stair tread overlays can be used.

When constructing stair tread overlays, the prior art typically employs a structure comprising a stair tread and a front nosing adhesively or otherwise secured to the stair tread at the front of the stair tread overlay. These front nosing members are subjected to considerable stress during use of the stairs, and the construction is prone to failure or breakage. The present invention is directed to solving these various problems.

SUMMARY OF THE INVENTION

An object, therefore, of the invention is to provide a new and improved stair tread overlay for installation on the stair steps of an existing stairway construction.

In the exemplary embodiment of the invention, the stair tread overlay includes a stair tread member having a top planar tread surface, a bottom surface for positioning on top of an existing stair step, and a front edge extending along the stair tread member and forming a nosing for receiving the weight of a user. A face strip member extends along the front of the stair tread member and projects downwardly from the bottom surface thereof. The face strip member is positioned beneath the nosing of the stair tread member and, thereby, is protected thereby. According to the invention, the stair tread member is fabricated of a more dense material for withstanding wear and tear on the overlay, and the face strip member is fabricated of a less dense material for facilitating shaping or machining of the face strip member.

According to some aspects of the invention, the face strip member has a top surface bonded to the bottom surface of the stair tread member beneath the nosing thereof. The face strip member has a front face which is flush with and forms a continuation of a front face of the nosing of the stair tread member. The face strip member has a back side for abutting against a front edge of the existing stair step and, thereby, properly position the stair tread overlay.

According to a further aspect of the invention, the stair tread member is fabricated of a high or medium density fiber board material, and the face strip member is fabricated of a lower density material.

The invention contemplates that at least the stair tread member be fabricated of a fiber board material covered by an imprinted film simulating a flooring surface. The face strip member also is covered by the imprinted film.

Other objects, features, and advantages of the invention will be apparent from the following detailed description taken with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of this invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with its objects and the advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which:

FIG. 1 is a front perspective view of an existing stairway construction on which the stair tread overlay of the invention may be installed;

FIG. 2 is a front perspective view of the stair tread overlay of the invention;

FIG. 3 is a front perspective view, exploded to better illustrate the two members of the overlay;

FIG. 4 is an end elevational view of the overlay;

FIG. 5 is a view similar to that of FIG. 4, with an imprinted film covering the top and front of the overlay;

FIG. 6 is front perspective view of the stair tread member of the overlay;

FIG. 7 is an end elevational view of the stair tread member;

FIG. 8 is a front perspective view of the face strip member of the overlay;

FIG. 9 is a front elevational view of the face strip member;

FIG. 10 is a perspective view illustrating the stair tread overlay about to be installed on the bottom step of the existing stairway construction of FIG. 1; and

FIG. 11 is a view similar to that of FIG. 10, with the stair tread overlay

Installed on the bottom step of the existing stairway construction.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings in greater detail, FIG. 1 shows an existing stairway construction, generally designated 12, which includes a number of stair steps, generally designated 12a, 12b and 12c. Although three stair steps are shown in FIG. 1, most existing stairway constructions would include more stair steps.

The existing stairway construction 12 may have been covered with carpeting which has been removed to expose existing lumber which includes stair step tread pieces 14 and front face pieces 15. Each stair tread piece 14 includes a top surface 14a and a front edge 14b.

FIGS. 2-4 show a stair tread overlay, generally designated 16, which includes a stair tread member, generally designated 18, and a face strip member, generally designated 20. This stair tread overlay is to be installed onto each of the stair steps 12a-12c of the stairway construction 12 shown in FIG. 1, as will be described hereinafter.

Stair tread member 18 of overlay 16 has a top planar tread surface 18a, a bottom surface 18b for positioning on top of the top surface 14a of one of the stair tread pieces 14 of the existing stairway. Stair tread member 18 also has a curved front edge 18c extending along the front of the stair tread member and forming a nosing for receiving the weight of a user, in conjunction with top tread surface 18a. In other words, stair tread member 18 extends all the way out to the front edge of the stair tread overlay.

Face strip member 20 of the stair tread overlay 16 extends along the front of stair tread member 18 and projects downwardly from bottom surface 18b of the stair tread member immediately below nosing 18c.

It can be seen in FIGS. 2 and 4 that face strip member 20 is protected by the front of stair tread member 18. Arrow â€œAâ€ (FIG. 4) shows the most likely direction of the weight of a user as the user steps up the stairway construction. It can be seen that face strip member 20 is completely protected by nosing 18c of the stair tread member. Therefore, face strip member 20 can be applied to bottom surface 18b of the stair tread member by simple adhesive in position beneath the nosing of the stair tread member. This adhesive can be applied to a top surface 20a of the face strip member. The face strip member has a front face 20b which can be made flush with and form a continuation of the front face of nosing 18c of the stair tread member, so that the front of the stair tread overlay is aesthetically pleasing. The face strip member has a back side 20c for abutting against a front edge 14b of the stair tread piece 14 of the existing stairway.

FIG. 5 shows that the top and front of stair tread overlay 16 is covered with an imprinted film 22 simulating a flooring surface. The film is shown somewhat separated from the top and front surfaces of the stair tread overlay, to facilitate the illustration of FIG. 5. Film 22 would typically be used when stair tread overlay 16 is fabricated of a fiber board material.

The invention contemplates that stair tread member 18 of the stair tread overlay be fabricated of a relatively hard, strong material for withstanding wear and tear on the overlay during use. The face strip member, being protected by the front of the stair tread member, therefore can be fabricated of a softer material for facilitating shaping or machining of the face strip member. FIGS. 8 and 9 show the face strip member having a very aesthetically pleasing contour which can easily be shaped with the softer material of the base strip member.

According to the invention, the stair tread member is fabricated of a more dense material than the face strip member. Stair tread member 18 can be fabricated of a high or medium density fiber board material, whereas the face strip member can be fabricated of a lower density material. The top and front of the stair tread overlay can be covered with film 22.

FIG. 10 shows one of the stair tread overlays 16 of the invention in the process of being installed onto the bottom step 12a of the existing stairway construction 12. When the stair tread overlay is seated onto the bottom step as seen in FIG. 11, the bottom surface 18b of stair tread member 18 rests on top of the top surface 14a of the bottom step. The back side 20c of face strip member 20 abuts the front edge 14b of stair tread piece 14 of the bottom step. In the alternative, a rear face 18d of stair tread member 18 can abut front face piece 15 of the second step, thereby eliminating any stress on the face strip member of the stair tread overlay.

Additional stair tread overlays 16 then are installed successively up the stair steps of the existing stairway construction, as described above in relation to the bottom step. Of course, the installation process can be reversed, starting with the top step of the stairway construction.

It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.