Structural support system

A structural support system of paired top and bottom rails connected by a plurality of vertically-oriented brackets, for use in construction settings such as truss arrangements and staircases. The rails have elongated slots for receiving and retaining connectors of the brackets. For staircase arrangements, the upper rail further includes an upper elongated slot for receiving step supports, and at least two paired top-bottom rails are positioned laterally for a step to be secured to upper surfaces of the laterally-adjacent step supports. Spacers can be employed in any or all of the slots for providing a desired distance between brackets or step supports.

FIELD OF THE INVENTION

The present invention relates to structural supports for buildings, and more specifically to structural supports for roofs and staircases.

BACKGROUND OF THE INVENTION

It is known in the construction industry to employ various forms of structural supports. For example, truss systems are commonly used to support building roofs. The structural support systems are of varied designs and materials, all selected by the skilled person as appropriate for the specific context.

In the setting of building roof construction, for example, trusses are used to provide structural support for the weight of the overlying roof materials. Such trusses are commonly composed of wood and often built off-site to desired specifications, with material-limited strength and limited flexibility for on-site modification.

In the context of staircase systems, and especially for exterior applications such as deck or walk-out settings, steps are supported by stringers running the length of the staircase. However, it is known in the art that strength and stability of such arrangements may be compromised with increasing staircase length, particularly with walk-out settings.

What is needed, therefore, is a support system that can be adapted to various structural support contexts while providing enhanced strength and stability compared to conventional systems.

SUMMARY OF THE INVENTION

According to a first broad aspect of the present invention, there is provided a structural support system comprising:

a top rail comprising a downwardly disposed opening extending along at least a part of the length of the top rail from an open top rail end;

a bottom rail comprising an upwardly disposed opening extending along at least a part of the length of the bottom rail from an open bottom rail end; and

at least one bracket, the at least one bracket comprising:

at least one upwardly directed connector slidably receivable within and along the downwardly disposed opening from the open top rail end, and sized and configured for retention within the downwardly disposed opening; and

at least one downwardly directed connector slidably receivable within and along the upwardly disposed opening from the open bottom rail end, and sized and configured for retention within the upwardly disposed opening.

In some exemplary embodiments of the first aspect, the at least one bracket comprises at least two brackets, with the connectors of each of the at least two brackets for inserting in series into each of the downwardly disposed opening and the upwardly disposed opening. Where there are at least two brackets, exemplary systems may further comprise at least one top rail spacer, the at least one top rail spacer configured for retention within the downwardly disposed opening situate between the upwardly directed connectors of two adjacent brackets of the at least two brackets. Exemplary systems may further comprise at least one bottom rail spacer, the at least one bottom rail spacer configured for retention within the upwardly disposed opening situate between the downwardly directed connectors of two adjacent brackets of the at least two brackets.

In some exemplary systems, the top rail further comprises an upwardly disposed opening extending along at least a part of the length of the top rail from an open top rail end, and the bottom rail further comprises a downwardly disposed opening extending along at least a part of the length of the bottom rail from an open bottom rail end.

In other exemplary systems, the downwardly disposed opening comprises a top rail flange, and the at least one upwardly directed connector comprises a notch for mating with the top rail flange, thus retaining the at least one upwardly directed connector within the downwardly disposed opening; and the upwardly disposed opening comprises a bottom rail flange, and the at least one downwardly directed connector comprises a notch for mating with the bottom rail flange, thus retaining the at least one downwardly directed connector within the upwardly disposed opening.

The top rail, the bottom rail, and the at least one bracket are preferably composed of aluminum.

According to a second broad aspect of the present invention, there is provided a staircase stringer system comprising:

a top rail comprising:

a downwardly disposed top rail opening extending along at least a part of the length of the top rail from an open top rail end; and

an upwardly disposed top rail opening extending along at least a part of the length of the top rail from the open top rail end;

a bottom rail comprising an upwardly disposed bottom rail opening extending along at least a part of the length of the bottom rail from an open bottom rail end;

at least one bracket, the at least one bracket comprising:

at least one upwardly directed bracket connector slidably receivable within and along the downwardly disposed top rail opening from the open top rail end, and sized and configured for retention within the downwardly disposed top rail opening; and

at least one downwardly directed bracket connector slidably receivable within and along the upwardly disposed bottom rail opening from the open bottom rail end, and sized and configured for retention within the upwardly disposed bottom rail opening; and

at least one step support configured for supporting a step, the at least one step support comprising at least one downwardly directed step support connector slidably receivable within and along the upwardly disposed top rail opening from the open top rail end, and sized and configured for retention within the upwardly disposed top rail opening.

In some exemplary embodiments of the second aspect, wherein the at least one bracket comprises at least two brackets, the connectors of each of the at least two brackets are for inserting in series into each of the downwardly disposed top rail opening and the upwardly disposed bottom rail opening. Where there are at least two brackets, exemplary systems may further comprise at least one lower top rail spacer, the at least one lower top rail spacer configured for retention within the downwardly disposed top rail opening situate between the upwardly directed bracket connectors of two adjacent brackets of the at least two brackets. Exemplary systems may further comprise at least one bottom rail spacer, the at least one bottom rail spacer configured for retention within the upwardly disposed bottom rail opening situate between the downwardly directed bracket connectors of two adjacent brackets of the at least two brackets.

In some exemplary embodiments, the at least one step support comprises at least two step supports, the system further comprising at least one upper top rail spacer, the at least one upper top rail spacer configured for retention within the upwardly disposed top rail opening situate between the downwardly directed step support connectors of two adjacent step supports of the at least two step supports.

According to a third broad aspect of the present invention, there is provided a staircase assembly comprising:

two top rails, each of the top rails comprising:

a downwardly disposed top rail opening extending along at least a part of the length of the top rail from an open top rail end; and

an upwardly disposed top rail opening extending along at least a part of the length of the top rail from the open top rail end;

two bottom rails, each of the bottom rails comprising an upwardly disposed bottom rail opening extending along at least a part of the length of the bottom rail from an open bottom rail end;

at least two brackets, each of the at least two brackets for connecting one of the two top rails to one of the two bottom rails to form paired top-bottom rail assemblies, the at least one bracket comprising:

at least one upwardly directed bracket connector slidably received within and along the downwardly disposed top rail opening from the open top rail end, and retained within the downwardly disposed top rail opening; and

at least one downwardly directed bracket connector slidably received within and along the upwardly disposed bottom rail opening from the open bottom rail end, and retained within the upwardly disposed bottom rail opening;

at least two step supports configured for supporting a step, each of the at least two step supports comprising at least one downwardly directed step support connector slidably received within and along the upwardly disposed top rail opening from the open top rail end, and retained within the upwardly disposed top rail opening; and

at least one step for securing to upper surfaces of the at least two step supports.

In some exemplary embodiments of the third aspect, the connectors of each of the at least two brackets are inserted in series into each of the downwardly disposed top rail opening and the upwardly disposed bottom rail opening. In some exemplary assemblies further comprising at least one lower top rail spacer, the at least one lower top rail spacer is retained within the downwardly disposed top rail opening situate between the upwardly directed bracket connectors of two adjacent brackets of the at least two brackets.

In some exemplary assemblies further comprising at least one bottom rail spacer, the at least one bottom rail spacer is retained within the upwardly disposed bottom rail opening situate between the downwardly directed bracket connectors of two adjacent brackets of the at least two brackets.

In some exemplary assemblies further comprising at least one upper top rail spacer, the at least one upper top rail spacer is configured for retention within the upwardly disposed top rail opening situate between the downwardly directed step support connectors of two adjacent step supports of the at least two step supports.

A detailed description of exemplary embodiments of the present invention is given in the following. It is to be understood, however, that the invention is not to be construed as being limited to these embodiments. The exemplary embodiments are directed to particular applications of the present invention, while it will be clear to those skilled in the art that the present invention has applicability beyond the exemplary embodiments set forth herein.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. The following description of examples of the technology is not intended to be exhaustive or to limit the invention to the precise form of any exemplary embodiment. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

Turning toFIG. 1, an exemplary support10is illustrated. The support10comprises a top rail12and a bottom rail14, with the rail pair12,14connected by a series of brackets16. As can be seen, the brackets16are oriented in an alternating arrangement, although the brackets16could also be oriented all in the same direction (as shown, for example, inFIG. 8a). The top rail12is of hollow construction and aluminum material in this exemplary embodiment, with a downwardly disposed slot or opening18extending the entire length of the top rail12between a first open end22and a second open end24. By having this slot18open at both ends22,24, brackets16and spacers40(described below) can be inserted into the slot18and slid along the slot18to be positioned at a desired location along the top rail12. The bottom rail14is also of hollow construction and aluminum material in this exemplary embodiment, with an upwardly disposed slot or opening20extending the entire length of the bottom rail14between a first open end26and a second open end28, again to allow the brackets16and spacers40to be slid into a desired position.

With further reference toFIGS. 2ato 2d, details of the exemplary bracket16are illustrated. Each bracket16comprises three connectors30, one at a single-connector side32and two at a double-connector side34, forming a generally triangular component of the support10. The single-connector side32is connected to the double-connector side34by means of bracket arms36, while the two connectors30of the double-connector side34are connected by means of a connection arm48. As can best be seen inFIG. 2d, each connector30comprises a notch or recess44—this notch44is configured to mate with a slot or opening, as will be described further below. When received within a slot or opening, the connectors30further comprise contact surfaces46a,bfor contact with the rail surface adjacent the slot or opening. The connection arm48provides further surface contact with the rail into which the bracket16is inserted.

FIG. 3aillustrates an exemplary top rail12, comprising two slots18and50differing in depth. As indicated above, the top rail12is of hollow construction, as can be seen from this end view. The connectors30of brackets16are configured to be inserted within the downwardly-disposed slot18. The slot18comprises a flange38, which slightly reduces the width of the slot18but provides a mating means for connection to the connectors30. As stated above, the connectors30comprise notches44. Upon insertion of the connector30into the slot18, the notches44mate with the flanges38, the flanges38thus retaining the connector30within the slot18as the bracket16is slid along the slot18to a desired location. The upwardly-disposed slot50and corresponding spacer52are directed to the staircase embodiment, described below.

FIG. 3cillustrates a spacer40from an end view perspective. Again, this component is of hollow construction and composed of aluminum. The spacer40comprises beveled edges42, which are configured to align with the flanges38of the slot18. As mentioned above, spacers40are sized and configured for insertion into and retention within the slot18, for separating the brackets16as desirable. A single spacer40would be employed between two adjacent brackets16, or multiple spacers40could separate a single pair of brackets16. Whereas the notches44of the bracket connectors30are intended to engage the flanges38to retain the brackets16in place, the spacers40are intended to be positioned entirely within the slot18and retained by means of the interface between the beveled edges42and the flanges38.

As can now be seen, the illustrated support10can provide a structural support means that is stronger and more stable than a single rail. For example, a support10of suitable length and material could be used in a roof truss system for supporting roof overlay, and can be assembled or modified onsite given the materials and the modular nature of the support10.

Turning now toFIGS. 3a, 3b, and 4ato 8c, a further embodiment of the present invention is illustrated, specifically an embodiment directed to using the present invention as part of a staircase arrangement.

As noted above with respect toFIG. 3a, the top rail12can be provided with an upwardly-disposed slot or opening50. The slot50is sized and configured to receive connectors58a,bof step supports56, in a manner similar to the bracket connectors30as described above.FIGS. 4ato 4eprovide a detailed illustration of such a step support56, which step supports56are intended to provide a foundation for mounting steps thereto at the support surface60. Each step support56comprises a connector58aand a spaced-apart connector58b, the connector58bmounted at the intersection of two step support arms64. The connectors58a,bare provided with contact surfaces62a,bfor contacting the top rail12when the connectors58a,bare inserted into the slot50and slid therealong into the desired position.

The connectors58a,bare again provided with notches/recesses68a,bsized and configured for mating with flanges38of the slot50, to enable the step support56to be retained thereby. Further, spacers52(as illustrated inFIG. 3b) can be positioned between adjacent step supports56, in any desired and appropriate number, the spacers52provided with beveled edges54to contact the flanges38and thus be retained within the slot50.FIGS. 5aand 5bshow an example of two step supports56separated by a spacer52housed within a slot50.FIG. 6illustrates an exemplary step support56and spacer52.

As indicated above, the intention is that steps would be mounted upon or affixed to the support surface60of the step support56. In use, there would be two or more laterally spaced-apart step supports56on two or more laterally spaced-apart staircase stringers. The steps can be mounted by any appropriate means known to the skilled person, but in one exemplary embodiment provided for illustrative purposes only the connection can be by screws passing through mounting holes66, as shown inFIGS. 7aand7b.

FIGS. 8ato 8cillustrate an exemplary staircase stringer70according to the present invention and the above teaching. The stringer70comprises paired top and bottom rails12,14, connected by brackets16separated by spacers40. The top rail12is further provided with step supports56, separated by spacers52. As can be seen, the arrangement allows for a series of step supports56extending along the length of the stringer70for attachment of steps in a conventional manner. To secure the stringer70in place, and to retain the brackets16, step supports56and spacers40,52in place, the first open ends22,24are provided with top caps72a,b, and the second open ends24,28are provided with foot caps74a,b. The caps72a,band74a,bmay be of conventional construction and materials, and would be affixed to supporting surfaces by conventional means well-known to the skilled person.

It will be clear, based on the foregoing, that embodiments of the present invention may have various advantages over conventional arrangements and techniques. In addition to the construction flexibility enabled by the modularity of the present invention, the use of paired top and bottom rails with strengthening brackets therebetween may provide a stronger and more stable support structure. In the case of staircase assemblies, it is possible to have longer stringers without the need for vertical support members than some conventional stringer designs.

While aluminum has been described herein as a desirable exemplary material, the skilled person will be aware of many other materials that could be used in other embodiments of the present invention.

Specific examples of methods and apparatus have been described herein for purposes of illustration. These are only examples. The technology provided herein can be applied to contexts other than the exemplary contexts described above. Many alterations, modifications, additions, omissions and permutations are possible within the practice of this invention. This invention includes variations on described embodiments that would be apparent to the skilled person, including variations obtained by: replacing features, elements and/or acts with equivalent features, elements and/or acts; mixing and matching of features, elements and/or acts from different embodiments; combining features, elements and/or acts from embodiments as described herein with features, elements and/or acts of other technology; and/or omitting combining features, elements and/or acts from described embodiments.

The foregoing is considered as illustrative only of the principles of the invention. The scope of the claims should not be limited by the exemplary embodiments set forth in the foregoing, but should be given the broadest interpretation consistent with the specification as a whole.