1. Field of the Invention
The subject invention generally relates to a ladder having excellent strength, rigidity, and weight.
2. Description of the Related Art
Generally, ladders, including fixed ladders, step ladders, step stools, and extension ladders, are formed from metals or combinations of metals and fiberglass. Metals and/or fiberglass are generally known to have excellent strength. However, even ladders formed from these materials may lack structural features which impart the ladder with sufficient strength and rigidity for use. Ladders formed from metals or combinations of metals and fiberglass can also be heavy and therefore difficult to manipulate and use. Additionally, ladders formed from metals generally require a significant amount of linkages, such as rivets or spot welding, therefore substantially increasing production time and cost of these ladders. Use of metals in ladders is further prohibitive in view of the increased cost of metals, such as aluminum and steel. One alternative material to metal which may be used to form ladders is thermoplastics.
While thermoplastics are often cheaper than metals, thermoplastics are not generally known for possessing those physical properties typical of metals, e.g. excellent strength and rigidity, which are required to form a safe, sturdy, and useful ladder. Accordingly, ladders formed from thermoplastics generally require more material than ladders formed from metals to impart the thermoplastic ladders with sufficient strength and rigidity, resulting in thermoplastic ladders that are generally heavier and therefore more difficult to operate than ladders formed from metals. One method to improve the strength of thermoplastics, and to reduce overall weight of ladders formed therefrom, is to include reinforcing fibers, such as glass fibers (fiberglass). Although thermoplastics reinforced with fiberglass have increased strength, ladders formed from these materials are still typically heavy and are therefore difficult to manipulate and operate.
Despite efforts using different materials such as metals, thermoplastics, or thermoplastics including reinforcing fibers to form ladders, concerns remain regarding the strength, rigidity, and weight of these ladders. Accordingly, there remains an opportunity to form an improved ladder.
A ladder includes a first stringer and a second stringer spaced transverse from the first stringer. The first and second stringers each define a channel and include a plurality of crosspieces disposed in the channels of the first and second stringers. A plurality of rungs are spaced along and coupled between the first and second stringers with each of the rungs including a horizontal portion and a vertical portion extending from the first stringer to the second stringer. The horizontal portion has a top surface and a bottom surface spaced from and opposite the top surface. The vertical portion extends generally perpendicularly away from the bottom surface of the horizontal portion and has a front surface and a rear surface spaced from and opposite the front surface. A plurality of ribs are spaced along and coupled between the horizontal and vertical portions of the rungs. The ribs extend from the bottom surface of the horizontal portion to at least one of the front and rear surfaces of the vertical portion.
The subject invention improves the strength and rigidity of the ladder by including the plurality of rungs having the horizontal and vertical portions with the plurality of ribs extending between the bottom surface of the horizontal portion to at least one of the front and rear surfaces of the vertical portion. The plurality of rungs including the plurality of ribs more efficiently spreads applied force and does so in a manner requiring less material, thereby minimizing weight of the ladder and improving ease of operation.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.
Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a ladder is shown generally at 20. The ladder 20 including the various embodiments described in greater detail below is suitable for use as a fixed ladder or as a step ladder. However, it should be understood that the ladder 20 is not limited to only those applications.
The ladder 20 comprises a first stringer 22 and a second stringer 24 typically spaced transverse from each other. Typically, the first and second stringers 22, 24 are parallel to and mirror images of one another. Additionally, each of said first and second stringers 22, 24 typically defines a channel 26. In one embodiment, each of the first and second stringers 22, 24 has a substantially C-shape cross-section that defines the channel 26. In this embodiment, the first and second stringers 22, 24 each have a base wall 28, a first wall 30, and a second wall 32 spaced transverse from the first wall 30. Typically, the first and second walls 30, 32 are generally parallel to one another and extend generally perpendicularly away from the base wall 28 giving the first and second stringers 22, 24 the substantially C-shape cross-section that defines the channel 26 as described above and as best shown in
In another embodiment, the first and second stringers 22, 24 individually terminate in a foot 34 having a tapered configuration as best shown in
A plurality of crosspieces 36 is disposed in the channels 26 of the first and second stringers 22, 24 to further increase strength and rigidity of the ladder 20, as best shown in
The ladder 20 also includes the plurality of rungs 38 spaced along and coupled between the first and second stringers 22, 24. In one embodiment, the rungs 38 are coupled between the first and second stringers 22, 24 between the channels 26 defined by the first and second stringers 22, 24. In another embodiment, the rungs 38 are coupled between the first and second stringers 22, 24 opposite from the channels 26 defined by the first and second stringers 22, 24 as best shown in
Each of the rungs 38 includes a horizontal portion 40 and a vertical portion 42. Typically, each of the horizontal and vertical portions 40, 42 extends from the first stringer 22 to the second stringer 24. In one embodiment, the vertical portion 42 of the rungs 38 flares out as the vertical portions 42 contact each of the first and second stringers 22, 24 as best shown in
The ribs 54 are spaced along and coupled between the horizontal and vertical portions 40, 42 of the rungs 38 as best shown in
In another embodiment, the ribs 54 includes a first set of ribs and a second set of ribs spaced and opposite the first set of ribs as best shown in
In second embodiment, the first set of ribs includes at least one first pair of ribs intersecting at a first point of intersection A to define a substantially V-shape and the second set of ribs includes at least one second pair of ribs intersecting at a second point of intersection B to define a substantially inverted V-shape as best shown in
In third embodiment, the first set of ribs includes the at least one first pair of ribs intersecting at the first point of intersection A to define a substantially V-shape and ribs 54 that are perpendicular to the bottom surface 46 of the horizontal portion 40 and therefore to the front surface 48 of the vertical portion 42, and the flange 52, if present, as best shown in
The ribs 54 provide the ladder 20, and more specifically the rungs 38, with excellent strength and rigidity. Accordingly, less material is required to imbue the ladder 20 with these physical properties than conventional ladders, contributing to the ladder 20 having excellent overall weight and ease of use.
In one embodiment, the ladder 20 further includes a support 56 as best shown in
The ladder 20, and the support 56 if present, may comprise any material. Typically, the ladder 20, and the support 56 if present, comprises a polymeric material. Suitable examples of polymeric materials include, but are not limited to thermoplastic and thermosetting polymers. One particularly suitable polymeric material is a polyamide. Examples of suitable polyamides include, but are not limited to, nylon 6 and nylon 6/6. In one embodiment, the polymeric material includes nylon 6 only, alternatively nylon 6/6 only, and alternatively various blends of nylon 6 and nylon 6/6. However, it should be appreciated that polymeric materials other than nylon may be used to manufacture the ladder 20. In another embodiment, the polymeric material includes additives to improve physical properties of the polymeric material.
Suitable additives include, but are not limited to, non-fiber impact modifiers, fiber-based impact resistance additives, coupling agents, pigments, glass or carbon fibers, mineral or glass beads, stabilizers, and combinations thereof. Although not required, the polymeric material is typically filled with fibers in an amount of from 20% to 75% by weight, alternatively from 30% to 65% by weight, alternatively from 35% to 60% by weight, alternatively from 35% to 50% by weight, alternatively from 50% to 60% by weight, alternatively from 30% to 40% by weight, alternatively from 45% to 55% by weight, and alternatively from 55% to 65% by weight, based on a combined total weight of the polymeric material and the fibers. The fibers improve the impact resistance with or without the non-fiber impact modifiers referenced above. Typically, the fibers are glass fibers; however it should be appreciated that the fibers may include other material or other materials in combination with glass. The fibers may vary in size (e.g. length, diameter, etc.) and may be coated or uncoated. For example, in one embodiment, it is preferred that the fibers have an average diameter of less than 20, alternatively from 5 to 20, alternatively from 6 to 16, alternatively from 10 to 15, alternatively 10, and alternatively 13, microns. The polymeric material or the fibers may each include other components to encourage bonding between the polymeric material and the fibers. Suitable examples of commercially available polymeric materials having fibers include, but are not limited to Ultramid®, Ultradur®, and Ultrafoam® polyamides commercially available from BASF Corp. In one embodiment, the polymeric material includes at least one of Ultramid® B3EG7, PA6, 35% glass filled by weight; Ultramid® B3EG10, PA6, 50% glass filled by weight; and Ultramid® HMG14 HS BK-102, PA66, 60% glass filled by weight.
Typically the polymeric material has a tensile modulus of from 6,000 to 22,000, alternatively from 7,000 to 21,000, alternatively from 6,000 to 8,000, alternatively from 10,000 to 12,000, alternatively from 18,000 to 22,000, and alternatively from 19,000 to 21,000, MPa when tested in accordance with ISO 527-1/-2 at 23° C. The polymeric material typically has a tensile stress at break of from 50 to 500, alternatively from 100 to 400, alternatively from 200 to 300, alternatively from 200 to 250, alternatively from 18,000 to 22,000, and alternatively from 19,000 to 21,000, MPa when tested in accordance with ISO 527-1/-2 at 23° C. Typically, the polymeric material has a tensile strain at break of from 1 to 5, alternatively from 2 to 4, and alternatively from 2.5 to 3.5, % when tested in accordance with ISO 527-1/-2 at 23° C. The polymeric material typically has a flexural strength of from 100 to 500, alternatively from 200 to 500, alternatively from 300 to 500, alternatively from 300 to 400, and alternatively from 350 to 400, MPa when tested in accordance with ISO 178 at 23° C. Typically the polymeric material has a flexural modulus of from 9,000 to 20,000, alternatively from 10,000 to 19,000, alternatively from 9,000 to 11,000, alternatively from 14,000 to 16,000, alternatively from 17,000 to 21,000, and alternatively from 18,000 to 20,000, MPa when tested in accordance with ISO 178 at 23° C. The polymeric material typically has a Charpy notched toughness of from 5 to 35, alternatively from 10 to 30, and alternatively from 12 to 25, kJ/m2 when tested in accordance with ISO 179/1EA at 23° C. and a Charpy notched toughness of from 5 to 25, alternatively from 10 to 20, and alternatively from 11 to 17, kJ/m2 when tested in accordance with ISO 179/1EA at −30° C. Typically, the polymeric material has a Charpy unnotched toughness of from 80 to 120, alternatively from 90 to 110, and alternatively from 95 to 105, kJ/m2 when tested in accordance with ISO 179/1EA at 23° C. and a Charpy notched toughness of from 70 to 110, alternatively from 80 to 105, and alternatively from 85 to 101, kJ/m2 when tested in accordance with ISO 179/1EA at −30° C. Typically the polymeric material retains the physical properties described above even after moisture conditioning.
The ladder 20 may be manufactured/formed using any method. Typically, the ladder 20 is formed via melt processing. Suitable examples of melt processing include, but are not limited to, injection molding, extrusion, compression molding, and vacuum forming. Typically, the ladder is formed via injection molding. Referring to the embodiment of the ladder 20 further including the support 56, both the ladder 20 and the support are typically formed via injection molding.
Typically, the ladder 20 is monolithic. Stated differently, the first and second stringers 22, 24, the crosspieces 36, the rungs 38, and the ribs 54 of the ladder 20 are integrally formed together as a single unit without joints or linkages. Referring to the embodiment of the ladder 20 further including the support 56, both the ladder 20 and the support are typically monolithic. In this embodiment, at least one linkage 64 is present for pivotally coupling the ladder 20 and the support 56. However, it should be appreciated that the ladder 20 may include additional joints or linkages.
In another embodiment, the ladder 20 is subjected to additional processing steps after formation. In one embodiment, the ladder 20 is “cored out”, i.e., material is removed from the ladder 20 after formation. For example, in this embodiment, a portion of the first and second stringers 22, 24 and the rungs 38 may be cored out where the rungs 38 contact the first and second stringers 22, 24. In the example above, the crosspieces 36 disposed in the channels 26 of the first and second stringers 22, 24 opposite the rungs 38, will extend through the cored out areas of the first and second stringers 22, 24 into the cored out area of and contacting the rungs 38 as best shown in
It is to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments which fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, it is to be appreciated that different, special, and/or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.
It is also to be understood that any ranges and subranges relied upon in describing various embodiments of the present invention independently and collectively fall within the scope of the appended claims, and are understood to describe and contemplate all ranges including whole and/or fractional values therein, even if such values are not expressly written herein. One of skill in the art readily recognizes that the enumerated ranges and subranges sufficiently describe and enable various embodiments of the present invention, and such ranges and subranges may be further delineated into relevant halves, thirds, quarters, fifths, and so on. As just one example, a range “of from 0.1 to 0.9” may be further delineated into a lower third, i.e., from 0.1 to 0.3, a middle third, i.e., from 0.4 to 0.6, and an upper third, i.e., from 0.7 to 0.9, which individually and collectively are within the scope of the appended claims, and may be relied upon individually and/or collectively and provide adequate support for specific embodiments within the scope of the appended claims. In addition, with respect to the language which defines or modifies a range, such as “at least,” “greater than,” “less than,” “no more than,” and the like, it is to be understood that such language includes subranges and/or an upper or lower limit. As another example, a range of “at least 10” inherently includes a subrange of from at least 10 to 35, a subrange of from at least 10 to 25, a subrange of from 25 to 35, and so on, and each subrange may be relied upon individually and/or collectively and provides adequate support for specific embodiments within the scope of the appended claims. Finally, an individual number within a disclosed range may be relied upon and provides adequate support for specific embodiments within the scope of the appended claims. For example, a range “of from 1 to 9” includes various individual integers, such as 3, as well as individual numbers including a decimal point (or fraction), such as 4.1, which may be relied upon and provide adequate support for specific embodiments within the scope of the appended claims.
The present invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described.
This application is the National Stage of International Patent Application No. PCT/US2012/052217, filed on Aug. 24, 2012, which claims priority to and all the advantages of U.S. Provisional Patent Application No. 61/528,535, filed on Aug. 29, 2011, the content of which is incorporated herein by reference.
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PCT/US2012/052217 | 8/24/2012 | WO | 00 | 2/27/2014 |
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WO2013/032887 | 3/7/2013 | WO | A |
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Number | Date | Country | |
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20140209412 A1 | Jul 2014 | US |
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61528535 | Aug 2011 | US |