STEYVERS, Johannes Matheus Hendrikus (Pannenweg 235, RK Nederweert, NL-6031, NL)
| CLAIMS 1. Stair renovation element for a stair tread which is suitable for renovating a stair tread by means of arranging thereof on an optionally pretreated, existing stair tread, comprising: - a stair tread cover member which is preformed in the form of the upper surface of a stair tread or which can be preformed in the form of the upper surface of a stair tread, - an upper surface which forms the upper side of the stair tread cover member during use, - a plastic protective layer for providing the upper surface with protection from the influences of envi- ronmental factors, such as chemical influences, high temperatures and/or the upper surface being walked on. 2. Stair renovation element as claimed in claim 1 wherein the plastic protective layer comprises a polymer which can be applied to the upper surface by means of a spraying or coating treatment. 3. Stair renovation element as claimed in one or more of the foregoing claims, wherein the plastic protective layer comprises a two-component material such as a two-component elastomer or a two-component thermoplastic. . Stair renovation element as claimed in one or more of the foregoing claims, wherein the protective laye comprises one or more of the following materials: poly- urea, polyurethane (PU) , polyester, nylon, polycarbonate, acrylonitrile butadiene styrene, aramid, bakelite, polyethylene terephthalate (PET) , polyethylene (PE) , such as HDPE , polyvinyl chloride ( PVC ) , polybutadiene (synthetic rubber) . 5. Stair renovation element as claimed in one or more of the foregoing claims, comprising a highly reactive two-component polyurea spray elastomer, preferably on the basis of a polyol and an isocyanate. 6. Stair renovation element as claimed in one or more of the foregoing claims, wherein the protective layer has a hardness of 30 to 100 shore D, preferably 60 to 90 shore D, more preferably 30 to 50 shore D, more preferably 80 to 100 shore A, more preferably 90 to 96 shore A. 7. Stair renovation element as claimed in one or more of the foregoing claims, wherein the material of the protective layer can be applied by means of a spraying operation, preferably under a pressure of 100 to 200 bar, more preferably 100 to 150 bar, more preferably 150 to 200 bar, more preferably 20 to 200 bar. 8. Stair renovation element as claimed in one or more of the foregoing claims, wherein the reaction times between two components for applying the protective layer lie in the range of 1 to 2000 seconds, preferably between 3 and 8 seconds, more preferably between 3 and 20 seconds, more preferably between 5 and 7 seconds, more preferably between 20 and 25 seconds, more preferably between 1000 and 2000 seconds, more preferably between 1400 and 1800 seconds. 9. Stair renovation element as claimed in one or more of the foregoing claims, wherein the processing tern- peratures during the spraying for the purpose of applying the protective layer preferably lie between 50 and 90¾, more preferably between 70 and 80°C, more preferably between 60 and 70°C, more preferably between 80 and 90°C, more preferably between 50 and 60eC. 10. Stair renovation element as claimed in one or more of the foregoing claims, wherein the protective layer has a fire resistance in a fire class B, more preferably Bl, more preferably B2, more preferably B3, more preferably Al, more preferably A2. 11. Stair renovation element as claimed in one or more of the foregoing claims, wherein the protective layer is made up of a first applied layer with a layer applied thereto for the purpose of providing an increased roughness . 12. Stair renovation element as claimed in one or more of the foregoing claims, wherein the protective layer comprises a granular material or a powder material for the purpose of providing roughness by a part of the granules or the powder protruding from the upper surface. 13. Stair renovation element as claimed in one or more of the foregoing claims, wherein the protective layer has a lower permeability, such as a water vapour permeability of less than 10, preferably less than 7, more preferably less than 6, more preferably less than 5, and/or a metal permeability of less than 100, more preferably less than 60, more preferably less than 50, more preferably less than 40, more preferably less than 30, more preferably less than 20. 14. Stair renovation element as claimed in one or more of the foregoing claims, comprising a nose element for covering the front side of the stair tread. 15. Method for manufacturing a stair renovation element as claimed in one or more of the foregoing claims, comprising steps for: - providing the plastic or at least a precursor for the plastic, - applying the plastic to the stair renovating element . 16. Method for manufacturing a stair renovation element as claimed in claim 15, comprising steps for im parting a property of roughness to the surface. 17. Method as claimed in claim 15 or 16, comprising steps for applying a base layer and steps for applying a roughening layer to the base layer, wherein these steps are preferably performed by means of successive spraying operations and/or coating operations. 18. Method as claimed in claim 15 or 16, comprising steps for adding a granular material and/or powder ma terial to the plastic for forming the protective layer fo the purpose of imparting roughness to the protective layer . |
The present invention relates to a stair renovation element for a stair tread which is suitable for reno- vating the stair tread by means of arranging thereof on an optionally pretreated, existing stair tread. The present invention also relates to a method for manufacturing the stair renovation element.
A trend has developed in recent years to have an existing staircase renovated by means of stair renovation elements. These known stair renovation elements provide an option for improving and renovating house staircases in characteristic manner. The upper side and/or the front side of a stair tread is provided here with a precisely placeable stair renovation element after optional cleaning and measuring of the specific size and/or form of the stair tread. Such stair renovation elements are generally manufactured from a material suitable for the purpose, such as MDF, with a laminated top layer providing the ap- pearance of a parquet floor.
The present inventor has noted limitations to such a known stair renovation element in specific applications. These include limitations with respect to the possible applications in environments with specific safety require- ments, such as a fire resistance, moisture resistance or resistance to chemical influences.
In order to obviate such drawbacks the present invention provides a stair renovation element for a stair tread which is suitable for renovating a stair tread by means of arranging thereof on an optionally pretreated, existing stair tread, comprising:
- a stair tread cover member which is preformed in the form of the upper surface of a stair tread or which can be preformed in the form of the upper surface of a stair tread,
- an upper surface which forms the upper side of the stair tread cover member during use,
- a plastic protective layer for providing the upper surface with protection from the influences of environmental factors, such as chemical influences, high temperatures and/or the upper surface being walked on.
It is an advantage of such a stair renovation ele- ment that it obviates the said limitations. Using a stair renovation element according to the present invention it becomes possible to fit the per se advantageous stair renovation element in the difficult conditions as noted. It hereby becomes possible to access a whole new market for stair renovation elements. With the correct plastic it becomes possible with use of the present invention to apply stair treads in and around chemical installations, factories and industrial premises where certain requirements are made in respect of fire resistance.
In a first preferred embodiment the plastic protective layer comprises a polymer which can be applied to the upper surface by means of a spraying or coating treatment. This change in the application of the protective layer makes it possible to apply suitable materials which will serve as protective layer. It also becomes possible to apply the protective layer in cost-effective manner and to provide an upper surface which also has an attractive appearance.
In a further preferred embodiment the plastic pro- tective layer comprises a two-component material such as a two-component elastomer or a two-component thermoplastic. Specific properties of the protective layer can be obtained as desired by applying a two-component material and these properties can be imparted in effective manner, for instance in that the raw materials can remain separated from each other until processing thereof.
Examples of suitable materials which can be used in the protective layer comprise: polyurea, elastomer polyurethane (PU), polyester, nylon, polycarbonate, acryloni- trile butadiene styrene, aramid, bakelite, polyethylene terephthalate (PET), polyethylene (PE), such as HDPE, polyvinyl chloride (PVC) , polybutadiene {synthetic rubber) .
More specific materials comprise a highly reactive two-component polyurea spray elastomer, preferably on the basis of a polyol and an isocyanate, such as 4.4'- methylene diphenyl diisocyanate . Materials which are specifically suitable here comprise for instance materials which can be supplied by the company Elastogran,
C6335/101, C6430/100 or relatively hard polyurethane materials.
The protective layer more preferably has a hardness of 30 to 100 shore D, preferably 60 to 90 shore D, more preferably 30 to 50 shore D, more preferably 80 to 100 shore A, more preferably 90 to 96 shore A. A high durability of the surface properties can be obtained by means of such hardnesses.
The material of the protective layer can prefera- bly be applied by means of a spraying operation, preferably under a pressure of 100 to 200 bar, more preferably 100 to 150 bar, more preferably 150 to 200 bar, more preferably 20 to 200 bar. A rapidly reacting material can be applied in reliable manner by applying such a pressure, wherein the desired material properties are obtained in respect of durability and the further stated desired properties . During application of the protective layer the reaction times between two components for the material for the protective layer more preferably lie in the range of 1 to 2000 seconds, preferably between 3 and 8 seconds, more preferably between 3 and 20 seconds, more preferably between 5 and 7 seconds, more preferably between 20 and 25 seconds, more preferably between 1000 and 2000 seconds, more preferably between 1400 and 1800 seconds. Within these ranges of reaction times materials can be applied, de- pending on their suitability therefor, by means of a very rapid spraying process or by means of a coating process which can be performed manually. The advantages stated in the foregoing are also hereby achieved.
In a further preferred embodiment the processing temperatures during the spraying for the purpose of applying the protective layer preferably lie between 50 and 90°C, more preferably between 70 and 80°C, more preferably between 60 and 70°C, more preferably between 80 and 90°C, more preferably between 50 and 60°C. Within these ranges of processing temperatures materials can be applied, depending on their suitability therefor, by means of an appropriate rapid spraying process, and optionally a slower coating process.
It is recommended that the protective layer has a fire resistance in a fire class B, more preferably Bl, more preferably B2, more preferably B3, more preferably Al, more preferably A2.
In a further preferred embodiment the protective layer is provided with a roughness so that it is possible to walk safely thereon. For this purpose the protective layer is preferably made up of a first applied layer with a layer applied thereto for the purpose of providing an increased roughness. The first layer provides a base for the protective layer and the second layer a structure providing the roughness- The first layer is preferably applied by means of coating or spraying. The second layer is preferably applied by means of spraying, whereby an appar- ently grainy surface is created when the above stated application parameters are applied.
In alternative manner the protective layer can comprise a granular material or a powder material for the purpose of providing roughness by a part of the granules or the powder protruding from the upper surface. In this case a single layer can preferably suffice with the granules and/or the powder incorporated therein.
In a further preferred embodiment the protective layer has a lower permeability, such as a water vapour permeability of less than 10, preferably less than 7, more preferably less than 6, more preferably less than 5, and/or a metal permeability of less than 100, more preferably less than 60, more preferably less than 50, more preferably less than 40, more preferably less than 30, more preferably less than 20. Hereby achieved is that durability is also retained in damp and/or chemically damaging conditions. The plate material serving as basis for the stair tread cover member is also protected and preserved .
The stair renovation element more preferably comprises a nose element for covering the front side of the stair tread. Both the upper side and the front side of the stair treads can hereby be renovated in simple manner by means of placing an element.
A further aspect of the present invention relates to a method for manufacturing a stair renovation element according to one or more of the foregoing claims, comprising steps for: - providing the plastic or at least a precursor for the plastic,
- applying the plastic to the stair renovating element. Such a method provides advantages as described in the foregoing with reference to the stair renovating element .
In an embodiment the method comprises steps for imparting a property of roughness to the surface in order to further provide said advantages.
Further advantages, features and details of the present invention will be described in greater detail hereinbelo on the basis of one or more preferred embodiments, with reference to the accompanying figures.
Fig. 1 is a schematic view of a first preferred embodiment according to the present invention.
Fig. 2 is a schematic view of a further preferred embodiment according to the present invention.
A first preferred embodiment (Fig. 1} according to the present invention relates to a stair renovation ele- ment designated with 1. The stair renovation element comprises a tread plate 2 and a nose plate 4. Tread plate 2 serves to cover and/or camouflage the original upper side of the tread after renovation. The nose plate serves to cover and/or to conceal the original front side, or nose, of the stair tread after renovation.
The surface part 7 of the upper plate as shown in figure 1 is untreated. Surface part 5 is provided with a first layer of polyurea material. This layer is applied by means of a rapid spraying, wherein the material finishes reacting in about 7 seconds after the two components have been brought together. It is important in obtaining the correct effect that the correct spraying technology be applied. The correct application method affects the quality of the layer and for instance the durability of the layer. The base layer can also be applied by means of a coating operation. This first layer is still relatively smooth and therefore unsuitable to be walked on as stair tread. This first layer does however provide a high protection factor for the underlying plate material.
In order to obviate this drawback a part of the stair tread is provided with a second layer. This second layer is applied by means of atomization or spraying. Rel- atively little material is used for this purpose, whereby only a partial coverage is obtained. This partial coverage is distributed over the whole surface. The specific method of spraying or atomizing and the specific material mix achieve that the material cures in a bubble-like form. This is achieved inter alia by the correct surface tension in the material in combination with the quantity of material sprayed over the surface. When not quite enough material is dispensed to provide a complete sprayed layer, the material cannot disperse fully due to the surface tension, and the "globules" are created over the whole surface. A surface is hereby provided which is rough, or can at least be walked on.
Fig. 2 shows a further variant according to the present invention. An untreated part 17 of the renovation element is also shown in this figure. The treated part 16 is however provided with a single layer which is applied to the surface with granular material or powder material therein. This granular material or powder material imparts a roughness to the surface, whereby it can safely be walked on. As layer 5 according to figure 1, the continuity of the material provides a good protection for plate material 17. It is also possible for layer 16 to be made up of two layers, wherein a base layer similar to layer 5 is first applied and subsequently a layer with granular material. It is also possible for the powder material or the granular material to be arranged after application of the layer while the material forming the layer has not yet finished reacting, whereby the powder or the granules can be incorporated and firmly adhered.
The present invention is described in the foregoing on the basis of several preferred embodiments. Different aspects of different embodiments are deemed as described in combination with each other. All combinations which can be understood by a skilled person in the field on the basis of this document are deemed to be described herein. These preferred embodiments are not limitative for the scope of protection of this document. The rights sought are defined in the appended claims.