Patent Abstract:
A step for installation into an attic that is easily installed on the existing beams within a typical attic to provide a safer and easier means to maneuver within a home&#39;s attic space. The step is produced using a single piece of sheet metal. In addition, the step is installed into the attic by securing teeth on the bendable tabs of the step to the existing beams using a hammer with the optional use of additional fasteners.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION AND CLAIM TO PRIORITY 
       [0001]    The present application is related to co-pending U.S. Provisional Application No. 61/895,637, filed Oct. 25, 2013, entitled ATTIC STEP, which is incorporated herein by reference, and claims priority thereto under 35 U.S.C. §119. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to an attic step, and in particular to an attic step that can be fastened to the existing truss beams typically found in attics. 
         [0003]    People need to maneuver around within a home&#39;s attic space during home construction and for maintenance and inspection requirements in existing homes. Because ceilings are attached to the underside of trusses, people have to be careful where they step in attics so as to avoid falling through or damaging the ceiling. This task can be particularly difficult when insulation covers part of or all of the ceiling, thereby making it more difficult for the person to determine where to step while moving around in the attic. The difficulty with this task can be enhanced when a portion of the trusses are also covered by insulation thereby making it unclear whether there is a board to step onto while moving around within the attic. 
         [0004]    Some people step into the V-shape where beams of the trusses meet, as a means for maneuvering in the attic. However, this approach is both inconvenient and dangerous as the person&#39;s foot is wedged at an angle and into a potential pinch point between the wooden beams of the trusses. Alternatively, permanent lumber can be installed on the horizontal portion of the trusses. However, installation of permanent lumber is time-consuming and expensive and also compresses the limits to the amount of insulation that can be used in the attic. The installation of permanent lumber can also add weight above the ceiling, thereby increasing the chances of the plaster or drywall cracking. It can also potentially restrict the expansion and contraction of the truss structure which can cause cracks in the plaster or drywall of the ceiling. Yet another way has been to use loose boards in the attic space and move them across the attic while a person attempts to traverse across the space. This too can be cumbersome and time-consuming and also compresses the insulation. 
         [0005]    While there are known ways for people to traverse around within an attic, improvements to products and methods for moving around the attic would be clearly advantageous, and are disclosed herein. 
       SUMMARY OF THE INVENTION 
       [0006]    According to one aspect of the present invention, an attic step includes a base with a plurality of flanges extending from at least one side of the base. The flanges are spaced apart to closely receive a truss beam. The attic step also includes a plurality of tabs extending from the base, with a plurality of teeth extending from the tabs. 
         [0007]    According to another aspect of the present invention, a method for installing attic steps in an attic includes forming an attic step from a single piece of metal. The step includes a base with two flanges extending from the left and right sides of the base. The flanges on each side are spaced apart to create a gap between the flanges. The step also has a tab extending from the left and right sides of the base. The step is placed over a truss such that at least one beam of the truss is closely received in the gap between the flanges on the left and/or right sides of the base. One or both tabs are bent to closely engage the truss beam(s). 
         [0008]    According to yet another aspect of the invention, a method of manufacturing an attic step includes selecting a piece of metal stock and stamping the piece to form a one-piece attic step. The attic step has a base, two flanges extending from the left and right sides of the base, a tab extending from the left and right sides of the base, and a plurality of teeth extend from each tab. 
         [0009]    The attic step can include any combination of one or more of the following features:
       Stamped sheet metal   An embossed surface that provides strength to the sheet metal while also providing an anti-slip surface   Flanges to provide rotational support of the step   Bendable tabs with built-in teeth for securing the step to wood trusses   Fastener holes through which fasteners can be inserted into the attic step to secure it to truss beam(s)   Alternative mounting configurations   Installation accomplished by using a hammer   A design that allows the attic steps to be stackable for ease of storage, transportation, or display of multiple attic steps.   A rubberized surface added to all of or a portion of the attic step to enhance the traction and/or durability of the attic step.       
 
         [0019]    These and other advantages of the invention will be further understood and appreciated by those skilled in the art by referencing the following written specification, claims, and appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]      FIG. 1  is a fragmentary perspective view of an attic step embodying the present invention, installed on truss beams. 
           [0021]      FIG. 2  is a perspective view of the attic step shown in  FIG. 1 . 
           [0022]      FIG. 3  is a fragmentary perspective view of a plurality of attic steps installed in an attic. 
           [0023]      FIG. 4  is a perspective view of a plurality of stacked attic steps. 
           [0024]      FIG. 5  is a fragmentary perspective view of the attic step with the flange shown in alternative positions, one of which is shown in phantom. 
           [0025]      FIG. 6  is a fragmentary top view of another embodiment of the base surface of the attic step. 
           [0026]      FIG. 7  is a fragmentary top view of another embodiment of the base surface of the attic step. 
           [0027]      FIG. 8  is a fragmentary top view of another embodiment of the base surface of the attic step. 
           [0028]      FIG. 9  is a fragmentary top view of another embodiment of the base surface of the attic step. 
           [0029]      FIG. 10A  is a fragmentary perspective view of the attic step before installation on truss beams. 
           [0030]      FIG. 10B  is a fragmentary perspective view of the attic step in place on truss beams. 
           [0031]      FIG. 10C  is a fragmentary perspective view of the attic step in place on a truss beam with an arrow showing the direction of force to be placed on the tab. 
           [0032]      FIG. 10D  is a fragmentary perspective view of the attic step with fasteners placed into the fastener apertures in the tabs. 
           [0033]      FIG. 11  is a top view of another embodiment of an attic step embodying the present invention. 
           [0034]      FIG. 12  is a perspective view of the attic step shown in  FIG. 11 . 
           [0035]      FIG. 13  is a front view of the attic step shown in  FIG. 11 . 
           [0036]      FIG. 14  is a side view of the attic step shown in  FIG. 11 . 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0037]    For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof, shall relate to the invention as oriented in the attached drawings. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting unless the claims expressly state otherwise. 
         [0038]    The inventive attic step  2 , shown in  FIG. 1 , can provide a safe and stable surface to walk on in an attic  20  that has truss beams  14 , as shown in  FIG. 3 . While the truss beams  14  are typically wood, the inventive attic step  2  can be used on beams made of other materials, including metal. In addition, the beams can have a rounded or milled edge  15 . The attic step  2  includes a base  4 , that operates as a step area, flanges  12 , and tabs  6 . As illustrated in  FIGS. 1 ,  2 , and  4 , the flanges  12  extend generally downwardly and slightly outwardly from the base  4  and the tabs  6  extend upwardly and slightly outwardly from the base  4 . 
         [0039]    As shown in  FIG. 2 , the flanges  12  have an outside surface  27  and an inside surface  28 . A gap  29  is formed between the inside surfaces  28  of corresponding flanges  12  on the right and left sides of the attic step  2 . The gap  29  is spaced to closely receive a beam  14  of an attic truss. Given that an attic beam has a width of approximately 1½ inches, the gap  29  will be approximately 1½ inches. The flanges  12  have an end  15  that is proximate the base and an end  13  that is distal from the base. While the gap  29  is illustrated as having a uniform width from the distal ends  13  to proximal ends  15  of the flanges  12 , the gap  29  may be tapered such that the width of the gap  29  that is nearest the proximal ends  15  of the flanges  12  is narrower than the width of the gap at the distal ends  13  of flanges  12 . Accordingly, the gap  29  can have a width of less than 1½ inches in between the proximal ends  15  of the corresponding flanges  12 . Because the truss beam(s) are closely received in the left and/or right gaps  29 , the corresponding flanges  12  provide rotational support of the attic step  2 . 
         [0040]    The tabs  6  are bendable at the end  9  of tab  6  that is proximate the base  4 . The distal ends  7  of the tabs  6  has a plurality of teeth  8 . The tabs  6  also have fastener apertures  10 . The tabs  6  can be bent so that the teeth  8  are inserted into a truss beam  14 . This can be accomplished by applying pressure to the tab  6  using a hammer or similar device. As illustrated in  FIG. 5 , tab  6  can be bent to engage a relatively flat beam  14 . When the tab  6 A (shown in phantom) is bent, the corresponding teeth  8 A and fastener apertures  10 A will also go into a similar orientation. 
         [0041]    While the illustrated attic  20  ( FIG. 3 ) includes insulation  18  and V-shaped trusses with beams  14 , it is to be understood that this attic step  2  may be used in attics  20  that do not include insulation  18  or that include trusses with beams  14  that are shaped such that the beams  14  do not come to a V-shape. As illustrated in  FIG. 1 , trusses do typically include multiple beams  14  that are connected by a plate  22 . As illustrated in  FIG. 3 , when the attic step  2  is installed in an attic  20 , the attic step can be placed such that the step area  4  is above the insulation  18  to create a path to allow a person to walk from truss to truss. 
         [0042]    As illustrated in  FIG. 2 , the base  4  includes a plurality of protrusions  16  to create a textured surface to increase the gripability of the base  4  for a person to step on. Such textured surfaces help prevent slipping by increasing the friction between a person&#39;s foot and the base  4  as compared to an entirely flat, non-textured surface. As illustrated in  FIGS. 6-9 , the textured surface of the base  4  can be altered to include any combination of surface texture to increase the gripability of the base  4  when a person steps on the attic step  2 . For example, in  FIG. 6 , the base  4  includes generally circular holes  34  that include a raised area  32 . With respect to  FIG. 7 , the base  4  can have a plurality of tread-like protrusions  36 .  FIG. 8  illustrates another textured surface for base  4  that includes raised areas  42  between holes  38  and  40 . Holes  38 ,  40  are elongated, with the holes  38  having raised protrusions.  FIG. 9  illustrates yet another exemplary embodiment of the base  4  with a plurality of holes  44  with corresponding rows of holes  44  offset to create a textured surface. Moreover, any combination of these embodiments or other textured surfaces (including, but not limited to, protrusions, indentations, and holes) can be used. In addition, a surface treatment can be added to the base  4 . For example, base  4  could have a rubberized surface, a sandpaper-like surface, or other surface applied to the one-piece metal attic step  2 . Such surfaces can be coated, sprayed, or adhered to the base  4  of the attic step  2 . In addition, such surface could also be added to other portions of the attic step  2 . 
         [0043]    The attic step  2  is installed on a truss  14  by lowering the attic step  2  onto the truss beams  14 , as illustrated by the arrow in  FIG. 10A . When the attic step  2  is placed onto the beam  14 , the beam  14  is closely received in the gap  29  between the flanges  12 . As illustrated in  FIG. 10B , the attic step  2  is placed in a generally horizontal orientation on beams  14  so that it is generally level. Once the attic step  2  is level, the tab  6  is advanced toward beam  14 , such that the teeth  8  are inserted into the beam  14 , as shown by the arrow in  FIG. 10C . Fasteners  26  can be inserted into fastener apertures  10  to further secure the tabs  6  and the attic step  2  to the beams  14  of the truss, as shown in  FIG. 10D . The fasteners  26  can be any conventional fastener, including, but not limited to, nails or screws. In addition, an adhesive (not shown) can be used to help secure the attic step  2  to the beams  14 , particularly when the beams  14  are metal. 
         [0044]    An additional embodiment of an attic step  52  is shown in  FIGS. 11-14 . The attic step  52  includes a base  54  that has protrusions  62  and holes  64 . The protrusions  62  can include a serrated or raised edge. The attic step  52  also includes tabs  56  and flanges  53  that extend from the base  54 . The tabs  56  have a pair of integrally formed teeth  58  at the distal ends  50  of the tabs  56  and a fastener aperture  60 . The end  51  of the tab  56  that is proximate the base  54  can include a hole  70 . The hole  70  can facilitate the bending of the tab  56  by creating less surface area at the end  51  where the tab  56  extends from the base  42 . 
         [0045]    The flanges  53  include outward edges  55  and inward edges  57  with a gap  59  between the inward edges of corresponding flanges  53 . The flanges  53  are spaced apart such that the gap  59  can closely receive an attic beam  14  as described above. 
         [0046]    The attic steps  2  and  52  are manufactured from a single piece of metal stock. The metal stock is stamped and/or cut to form a one-piece attic step  2 ,  52  that has an integral base  4 ,  54  with integral flanges  12 ,  53  and integral tabs  6 ,  56  with teeth  8 ,  58 . For example, the attic step  2  can be made in a progressive metal forming die. As described above, surface texturing or treatments may be applied to the attic step  2 . 
         [0047]    As illustrated in  FIG. 4 , the attic step is shaped so that multiple attic steps can be stacked one upon the other to make storage, shipment, and installation of the attic steps easier to accomplish. 
         [0048]    It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. 
         [0049]    It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of textures and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. 
         [0050]    It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting. 
         [0051]    It is also to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Technology Classification (CPC): 8