Patent Application
20140116804
1. Field of the Invention
The present invention relates generally to the building construction and related trades and, more particularly, to an improved convertible support pad apparatus for ensuring the proper and safe distribution of weight loads and stable footing upon an underlying generally level or sloped working surface.
2. Description of the Prior Art
In the building construction and related trades, it is important to provide the means for the construction worker to work safely and efficiently upon underlying sloped or generally level surfaces, such as, for example, inclined and flat roofs, and all types of terrain. As disclosed in U.S. Pat. No. 8,104,575 B1 issued Jan. 31, 2012, to Bancroft, a support pad apparatus is provided for ensuring the proper distribution of weight loads comprising, for example, the gross weight of the construction worker, the worker's tools and/or equipment and construction materials, and stable and secure footing, particularly while the worker is operating on inclined or heavily sloped roof surfaces.
In the prior art, in addition to Bancroft, is U.S. Pat. No. 6,490,842 B2 issued Dec. 10, 2002 to Emmons, which is directed to a traction pad for use in roof-related repairs of a sloped roof. The device includes a traction pad for maneuvering on a roof and contains a base layer, a traction layer, and at least two traction cross members and two end members. The base and traction layers are preferably rectangular in shape. The bottom surface of the base layer engages the roof surface, with the traction layer attached to the top surface. At least two traction cross members are attached to the top surface across its length. The two end members are attached adjacent the ends of the two traction cross members. The top surface of the traction layer is typically covered with a paint containing sand to provide improved traction. The Emmons invention has several drawbacks, as follows: the cross members, because their configuration is triangular, more particularly because the shape of the apex of the triangle is too sharp, do not provide reliable footing when the traction pad is disposed upon underlying steep surfaces and, thus, are unsafe. Further, workers will most certainly find it uncomfortable and possibly even painful to kneel down or sit upon the traction pad, particularly the apex of the cross members, when circumstances may require them to do so. Also, the lifting handles projecting from the top sides of the two end members, because of the risk that a worker may trip and stumble over them, are inherently hazardous. The Emmons invention is also a relatively complicated apparatus requiring the assembly of at least seven separate components and twenty-five to thirty screws and bolts to secure all the connections.
Also a part of the prior art is U.S. App. Publication No. 2003/0037990 A1 directed to a pad providing protection, safety and stabilization to a worker on a sloped surface, which has the added benefit of protecting the sloped surface itself. The pad is flexible to effectively grip or attach itself to a sloped surface, and contains a multitude of indentations or footholds on the upper surface for engagement of the worker's shoes to provide stability.
The disadvantages of the prior art devices are numerous, including that none of them have the significant structural reinforcement that is embodied in the improved support pad apparatus of the present invention, that none embodies the convertible nor the several other important novel features of the present invention, all of which contribute to the improvement of the construction worker's footing and balance, when working on a variety of underlying surfaces. These include conventional sloped roofs, level surfaces or terrain, such as a flat roof, or surfaces consisting of exterior hardscape, sloped or level. Not until the conception and reduction to practice of the improved support pad apparatus of the present invention has a device addressed these and so many other significant shortcomings prevalent in the prior art.
The preferred embodiment of the present invention provides an improved support pad apparatus for distribution of weight loads and enabling the worker greater stability and balanced footing when walking upon an underlying generally level or sloped surface. The improved support pad apparatus includes a base platform having a first side and a second side, a front end with a front side and a back end with a back side, a top surface and a bottom surface, one or more cleat members attached to or integrally formed within the top surface, and one or more cross members disposed in parallel relation across and formed integrally within or attached to the top surface. Each cross member includes a top section with a top surface, and first and second sidewalls with each of the sidewalls having a bottom portion running along its entire length. The cleat members and the cross members combine to provide support to the construction worker's footing to compensate for any difficult angle of inclination formed by the underlying surface, typically a sloped roof, and to enable the oblique orientation of the person's generally upstanding body relative to the angle of inclination to ensure proper balance and greater safety on the job.
Also provided is a riser member detachably connected to the area of the top surface of the base platform that is adjacent to the bottom portion of the sidewalls of each of the cross members. Each riser member, which conforms generally to the shape of the cross member, gives the cross member additional height and surface area to enable improved and more stable and safe footing for the worker. Each riser member also has a first and a second sidewall with each sidewall having a bottom edge. Additionally provided is a resilient pad attached to the bottom surface of the base platform for substantially conforming to the shape and contours of the underlying surface and receiving and distributing a weight load over the top surface to protect the underlying surface from damage.
The preferred embodiment of the present invention also includes a cover platform for placement upon the base platform in overlaying relation for converting the base platform for use on a substantially level underlying surface. The bottom surface of the cover platform includes a plurality of reinforcing support rib members to provide strength and rigidity to the cover platform. This enables the base and cover platforms, when joined, to be utilized on generally level underlying surfaces, indoors and outdoors, and to accommodate and distribute, due to the enhanced strength of the combined platforms, increased weight loads. Adjacent support rib members are disposed laterally in spaced parallel relation and also linearly in spaced relation forming slotted openings along a plane transverse to the axis of the linearly disposed support rib members for receiving the cross members in conformal relation. This enables a secure and stable connection between the base and cover platforms to ensure a strong rigid support structure. The support pad apparatus of the present invention also includes a leveling insert and a storage unit, as more particularly described in the Detailed Description of the Preferred Embodiment below.
Accordingly, it is an object of the present invention to provide a support pad apparatus that embodies the means for improved structural reinforcement when subjected to increased weight loads.
Another object of the present invention is to provide a support pad apparatus that employs the means to easily and quickly convert from a platform for use on sloped surfaces to a platform deployable on generally flat or level surfaces.
Still another object of the present invention is to provide a support pad apparatus with the means to convert to a hybrid platform to enable the construction worker to operate on both sloped and level platforms without the need to entirely convert to one or the other.
Still another object of the present invention is to provide a support pad apparatus with the means to accommodate compartments to hold or store equipment, tools and/or construction materials.
Still another object of the present invention is to provide a support pad apparatus that includes the means to improve the construction worker's footing and balance while operating on a sloped underlying surface, especially those that are steeply inclined.
Still another object of the present invention is to provide a support pad apparatus that is easy and cost effective to manufacture.
Still another object of the present invention is to provide a support pad apparatus that is relatively lightweight and easy to transport.
Other objects and advantages of the present invention will become apparent in the following specifications when considered in light of the attached drawings wherein the preferred and alternative embodiments of the invention is illustrated.
The features of this invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as its organization and manner of operation, together with further objects and advantages thereof, may be best understood by reference to the following detailed description, taken in conjunction with the accompanying drawings.
The improved support pad apparatus 10 of the present invention is employed principally for the purposes of distributing weight loads, normal and extraordinary, enabling the construction worker more stable footing and ensuring proper balance for a construction worker operating upon an underlying generally level or sloped surface. Support pad apparatus 10 includes base platform 12 having first side 14 and interior wall 14a, second side 16 and interior wall 16a, front end 18 with front side 20 and interior wall 20a, and back end 22 with back side 24 and interior wall 24a. Also included is top surface 26 and bottom surface 28 and one or more cleat members 30, which are generally triangular in shape, but with a blunted or rounded tip or apex 35 attached to or integrally formed within top surface 26 along with two or more cross members 32, which are generally rectangular in shape, disposed in spaced relation across and formed integrally within or attached to top surface 26. Cleat members 30 may also be configured more rectangularly. Each cross member 32 includes top surface 33 with openings 37 formed at opposite ends to attach two or more base platforms 12 end to end, first sidewall 34 and second sidewall 36 with each sidewall 34, 36 having base portion 38 extending the length of the sidewall. The typical dimensions of base platform 12 are 2′ in width by 4′ in length, and about 4″ thick, although these dimensions may vary. Preferably, base platform 12 is molded as a single unit, though the platform can also be fabricated by joining together certain combinations of the individual components of the platform (e.g. sides 14, 16, 20 and 24, and top surface 26, as one united component, with cleat members 30 and cross members 32 joining separately) using any suitable and conventional attachment means for this purpose.
Cleat members 30 and cross members 32 are provided to give enhanced support to a person's footing to compensate for the angle of inclination formed by the underlying surface, for example, sloped roof 40, enabling the oblique orientation of the person's generally upstanding body relative to the angle of incline to ensure proper balance and a safer working condition.
Riser member 42 is detachably connected to the area of top surface 26 adjacent to base portion 38, which runs along the entire length of each cross member 32. Riser member 42 conforms generally to the shape of each cross member 32 and is disposed upon cross member 32 to give it additional height and surface area along its sidewalls. This enables construction worker 47 improved and much more reliable footing, particularly upon steeply inclined underlying surfaces. Riser member 42 includes a top section 43, with a top surface 45 and first side 44 and second side 46 with first side 44 including first bottom edge 48 and second side 46 including second bottom edge 50. Riser member 42 is typically 1½″ in height, which adds ½″ to the height of cross member 32 which, in the preferred embodiment, is 1″ in height. To further secure riser member 42 to cross member 32, first side 44 and second side 46 are oriented slightly inward to form an approximately 80° interior angle at each vertex where top section 43 joins first side 44 and second side 46 to ensure a relatively tight friction fit for riser member 42 when it overlays cross member 32.
Resilient pad 52, which is comprised of a conformable material, such as polyethylene foam or rubber, is attached to bottom surface 28 using any suitable attachment means for this purpose, such as, for example, strong adhesive. Resilient pad 52 is provided for substantially conforming to the shape and contours of the underlying surface, whether the surface is sloped or generally level, or exists within, on top of or outside of a building, or any other type of structure. Base platform 12 combines with resilient pad 52 to receive and distribute weight loads over top surface 26 to protect against damage to the underlying surface and provide a frictional base to hold support pad 10 securely to the underlying surface.
Disposed adjacent to one or more base portions 38 of corresponding sidewalls 34, 36 are one or more openings 54, and attached to or formed integrally with first bottom edge 48 and second bottom edge 50 of each riser member 42 are mating projecting pins 56 adapted to fit slidably into openings 54 in releasable engagement for further securing each riser member 42 to cross member 32. Opening 54 may also be slotted (not shown) to accommodate a projection, which, as with projecting pin 56, is attached to or formed integrally with bottom edges 48,50, but shaped more like a “key”, which is configured flatter and wider than projecting pin 56.
Cover platform 60 is adapted for placement upon base platform 12 in overlaying relation for converting base platform 12 for use on a variety of generally level surfaces, such as, for example, a flat roof surface 62 or upon an exterior hardscape (not shown). Cover platform 60 includes top surface 64 with an applied textured material 39, such as, for example, some type of paint with sand mixed in, or an embossed patterned surface (not shown), to provide better footing. Also provided are bottom surface 66, first side 68 and second side 70, front end 72, including front side 74, and back end 76, including back side 78, and slotted opening 75 for use in joining two or more platforms together and in transporting them to different locations. Bottom surface 66 includes a plurality of reinforcing support rib members 80 with spaced opposing ends 82,84 for providing greater strength and rigidity to cover platform 60. Cover platform 60 includes an integrally surrounding down-turned rim 130 formed from first side 68, second side 70, front side 74 and back side 78, with spaced sections 132 for accommodating cleat members 30, cross members 32 and slotted openings 75 when cover platform 60 is installed upon base platform 12 and settles into position. First side 68 includes section members 134a,136a which define both an opening 138a and integrally formed elongated bearing member 140a to accommodate and support cleat members 30 positioned beneath. Section members 136a,142a define opening 144a for accommodating cross members 32 in conformal relation. Section members 146a,148a and 150a define opening 152a for accommodating slotted opening 75 in aligned relation. Second side 70 consists of the respective counterparts from the opposite side of cover platform 60, including section members 134b,136b,140b,142b,146b,148b, and 150b, and openings 138b,144b and 152b.
Two or more support rib members 80 are disposed laterally in spaced relation. Support rib members 80 are also disposed linearly in spaced relation to form slotted openings 86 between respective spaced ends 82,84 for receiving cross members in each of the slotted openings in conformal relation. When cover platform 60 overlays base platform 12, support rib members 80 are positioned transverse to the orientation of cleat members 30 and rest upon or are supported by cleat members 30 when the two platforms unite. The joinder of these platforms, as described, further secured by the frictional fit made possible by the engagement of the slightly spread or flared sides 68,70,74 and 78 against respective interior walls 14a, 16a,20a and 24a, enables a more secure and stable union between base platform 12 and cover platform 60 to further enhance the rigidity of the combined support structure. Cover platform 60 may be comprised of any suitable material including, without limitation, synthetic resins and a variety of metal alloys, including steel and aluminum. Approximate dimensions of cover platform 60 are, as follows: 4′ in length, 2′ in width and 1¼″ in height. These dimensions may vary depending upon several factors, including the dimensions of base platform 12.
Base platform 12 and cover platform 60 include one or more openings 68 in each for receiving the means for further securing the platforms together. Means for securing platforms 12 and 60 include, for example, straps 90 and rope 92, and customized clips or ties made from any suitable material (not shown).
Support rib members 80 are attached to bottom surface 66 utilizing means from the group of items comprised of spot welds 94, and rivets, staples, screws and bolts, or a variety of other items suitable for this purpose (not shown). Support rib members 80 may also be pressed from the synthetic or metal alloy material comprising base platform 12 utilizing any suitable tool die for this purpose or alternatively fabricated by carving support rib members 80 from the same material employing any other suitable method to create an embossed or raised projection.
Support pad 10 may also include leveling insert 100, which overlays a group of cleat members 30 in the section of top surface 26 between any two cross members 32, and is disposed conformably therein with top surface 102 of insert 100 disposed at exactly or generally at about the same height as top surface 33. Leveling insert 100 also includes bottom surface 104, which has a series of transverse ribs 106. When, leveling insert 100 is caused to overlay cleat members 30, as described, transverse ribs 106 rest upon cleat members 30 and fit conformably in the space situated beneath. Leveling insert 100 also includes first side 120, second side 122, front side 124 and back side 126, all of which are flared or slightly bent outwardly to enable leveling insert 100 to frictionally fit securely within the spaces between any two cross members 32 employing the same principle applied to secure the connection that cover platform 60 utilizes to secure itself to base platform 12. Approximate dimensions of leveling insert 100 are, as follows: 20″ in length, 12″ in width and 1″ in height. These dimensions may vary depending upon several factors, including the dimensions of base platform 12. Leveling insert 100 may be comprised of a variety of materials including, but not limited to, synthetic resin and metal alloys, such as steel and aluminum.
Support pad 10 may also include storage container 108, which may either be attached or simply laid upon top surface 26 of base platform 12. Storage container 108 includes one or more compartments 110 for carrying or holding tools, construction materials and any other type of item typical of the construction trade. Integrally formed with or attached to storage container 108 are one or more openings 112, which can be used for securing container 108 to base platform 12, one or more openings 113, which are used primarily for lifting or transporting storage container 108, but which may also be used as a means to secure container 108 to base platform 12 with the addition of a connector strap or rope employed for this purpose. Storage container 108 also includes a continuous skirt portion 114 with a slight inward bent for frictionally seating container 108 conformably about sides 14,16,20 and 24 of base platform 12, in an overlaying fashion for securing one upon the other. An alternative version of storage container 108 is one that overlays the perimeter of base platform 12 leaving interior space available for tools and materials. Separate dividers (not shown) may be installed for holding tools, or segregating tools and materials, as required. Approximate dimensions of storage container 108 are, as follows: length 4′½″, width 2′⅜″ and height 8″. Storage container 108 may be comprised of a variety of materials including, without limitation, synthetic resins and metal alloys, such as steel and aluminum.
This invention has been described in its presently preferred embodiment, and it is clear that it is susceptible to numerous modifications, modes and embodiments within the ability of those skilled in the art and without the exercise of this inventive faculty.
