The present invention is related to a ladder having box rails with rungs attached to the box rails using collars about the rungs in between the inner and outer webs of the rails. (As used herein, references to the “present invention” or “invention” relate to exemplary embodiments and not necessarily to every embodiment encompassed by the appended claims.) More specifically, the present invention is related to a ladder having box rails with rungs attached to the box rails using collars about the rungs in between the inner and outer webs of the rails where the collars snap into the rails.
This section is intended to introduce the reader to various aspects of the art that may be related to various aspects of the present invention. The following discussion is intended to provide information to facilitate a better understanding of the present invention. Accordingly, it should be understood that statements in the following discussion are to be read in this light, and not as admissions of prior art.
When box rails are used for a ladder, the rungs or steps must be securely and safely attached to the box rails. However, because box rails do not have anything in between the opposing webs, the webs are susceptible to damage, such as cracking or denting when perpendicular forces are applied to them to attach the rung to the rail, such as by swaging the end of the rung to the outer web. In order to avoid any damage to the webs during the rung attachment process, typically some type of collar must be positioned inside the rail between the webs to support the opposing webs when the swaging process occurs. To accomplish this, collars have been inserted down the length of the rails having adhesive to hold the collars and the desired position, which is a tedious and time-consuming operation, let alone not always positioning the collars properly in place with the adhesive.
The present invention pertains to a ladder. The ladder comprises a right box rail having an outer web with an outer opening and an inner web with an inner opening. The inner opening in alignment with the outer opening. The inner opening having a diameter which is smaller than a diameter of the outer opening. The ladder comprises a left box rail in parallel and spaced relation with the right box rail. The ladder comprises a hollow collar disposed in between the inner opening of the inner web and the outer opening of the outer web. The collar having a stem having a plurality of segments. The segments separated by slots. Each segment having a top and a bottom. The ladder comprises a first rung attached to the right and left box rails. The first rung having a right end that extends through the outer opening, the collar and the inner opening.
A method for forming a ladder. The method comprises the steps of inserting a hollow collar in between an inner opening of an inner web and an outer opening of an outer web of a right box rail of the ladder. The collar having a stem having a plurality of segments. The segments separated by slots. Each segment having a top and a bottom. The inner opening having a diameter which is smaller than a diameter of the outer opening. There is the step of extending a right end of the first rung through the inner opening, the collar and the outer opening. There is the step of fixedly attaching the right end of the first rung to the outer web. There is the step of fixedly attaching a left end of the first rung to an outer web of a left box rail.
The present invention pertains to a method for using a ladder by a user. The method comprises the steps of moving the ladder to a desired location. There is the step of positioning the ladder for a user to climb the ladder.
In the accompanying drawings, the preferred embodiment of the invention and preferred methods of practicing the invention are illustrated in which:
Referring now to the drawings wherein like reference numerals refer to similar or identical parts throughout the several views, and more specifically to
The collar 24 may have a hollow base 38 with a cross-sectional shape which conforms with a cross-sectional shape of the first rung 36. The first rung 36 extending through the base 38 and the stem 26. The bottom 34 of the segments 28 directly attached to the base 38. The tops of the segments 28 defining an outer stem circumference 40 which is larger than an outer circumference of the base 38. See
The top 32 of each segment 28 may have a ridge 42. The ridge 42 having a lower portion 44 which fits in the outer opening 18 in the outer web 16 and directly contacts a surface of the outer opening 18. The ridge 42 having an upper portion 46 which directly contacts an inner surface of the outer web 16. The upper and lower portions 46, 44 of the ridge 42 form a catch 47 with the outer web 16. The ridges 42 of the segments 28 together assist in holding the collar 24 in place in the rail.
An outer surface of the plurality of segments 28 may angle upwards from the bottom 34 to the top 32. The outer surface acting as a cam when the collar 24 is inserted through the outer opening 18 in the outer web 16 where the surface of the outer opening 18 causes the plurality of segments 28 to move down as the plurality of segments 28 moves through the outer opening 18.
The collar 24 may be made of plastic. The collar 24 may be a single piece. The ladder 10 may include a bead 48 disposed on and positioned about the rung adjacent the right end 50 and in contact with the inner web 20 of the right box rail 12. An edge 52 of the right end 50 of the first rung 36 may roll over against the outer web 16 about the outer opening 18. The rung may have a profile of a D shape. The ladder 10 may include a second rung 54 attached to the first and second box rail. The first rung 36 may be hollow. The first rung 36 and the first and second box rails may be made of metal.
In the operation of the invention, a collar 24 is disposed between the webs of a box rail. The collar 24 supports the webs when a connection is made between a beaded and swaged rung and the rail. The collar 24 is easily inserted in the rail by snapping into place from one side of the rail. The collar 24 provides a means of securely joining rungs to box rails without the danger of deforming or cracking the thin webs of a typical box rail. The use of a snap in collar 24 is simpler, less expensive, and faster than alternate techniques such as inserting collars down the length of a box rail and using adhesive.
With reference to
When the swaging process occurs, the inner web 20 an outer web 16 will not buckle inwards or crack or be damaged because the collar 24 is present to receive the compressive loads that are applied in the swaging process and effectively hold the outer web 16 an inner web 20 in place and apart. That is, the segments and base of the collar 24 act as support walls supporting the inner and outer webs against the compressive loads.
A collar 24 is snapped into all the openings of the right and left rails, in the process described above is then repeated for the end of each rung to attach each rung to the right and left rails of the ladder 10.
Alternatively, instead of the outer web opening 18 having a larger circumference than the inner web opening 22, this can be reversed so the outer web opening 18 has a smaller circumference than the inner web opening 22. In this alternative embodiment, the collar 24 is then inserted through the inner web opening 22, with everything occurring as described above.
Although the invention has been described in detail in the foregoing embodiments for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be described by the following claims.
This application claims priority from U.S. provisional application Ser. No. 62/954,276 filed Dec. 27, 2019 and U.S. provisional application Ser. No. 62/954,290 filed Dec. 27, 2019, both of which are incorporated by reference herein. This application also incorporates by reference U.S. patent application Ser. No. 16/795,086, filed concurrently with this application on Feb. 19, 2020; and incorporates by reference U.S. patent application Ser. No. 16/795,132, filed concurrently with this application on Feb. 19, 2020.
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