Rolled fabric dispensing apparatus and fall protection system and method

Information

  • Patent Grant
  • 6595455
  • Patent Number
    6,595,455
  • Date Filed
    Thursday, May 17, 2001
    23 years ago
  • Date Issued
    Tuesday, July 22, 2003
    21 years ago
Abstract
Apparatus for dispensing a rolled fabric across the width of at least two longitudinal structural supports. In some embodiments, apparatus which is capable of forming a fall protection system which conforms to OSHA standards when constructing metal insulated roof systems.
Description




FIELD OF THE INVENTION




This invention relates to apparatus for dispensing a rolled fabric across the width of at least two longitudinal structural supports and, in particular embodiments, to apparatus capable of forming a fall protection system which conforms to OSHA standards when constructing metal insulated roof systems.




BACKGROUND OF THE INVENTION




Metal roof structures are typically comprised of a series of rafters which extend parallel to each other from each side of a building to its roof peak. Longitudinal structural supports (eg. purlins or bar joists) are typically mounted on top of and perpendicular to these rafters in a similarly parallel fashion.




In one manner of constructing such a known metal roof structure as described, a fabric (eg. polyethylene) is first rolled in sheets over these purlins. These sheets then serve as a vapor barrier for the metal roof structure. Once the insulation is installed over the sheet of fabric, the insulation is secured in place with hard (typically metal) roof sheeting attached to the upper surface or flange of the purlins.




Heretofore, it has been known in the art to install fabric across the top of purlins by hand or by various carriage devices such as illustrated in U.S. Pat. No. 5,495,698. Installation by hand is often quite time consuming and labor intensive and gives rise to certain safety problems particularly during unusual weather conditions such as high winds. Federal and state OSHA regulations have been passed to enhance safety in this regard through the mandated use of fall protection devices.




In particular, the purlins on which an insulation installer must work are typically located at a considerable height above ground level. Because an installer is working at such heights, there is substantial risk of both personal injury and death if an installer/laborer falls from the roof surface. Various fall protection devices have been designed specifically to prevent such injuries or deaths from occurring. One such prior art device is known commercially as Elaminator® and is employed by Owens Corning Fiberglass, Inc. and its various contractors to install metal, insulated roof systems. This fall protection system is believed to be disclosed in U.S. Pat. No. 6,195,958 and includes a cantilever type structure (e.g. a metal plate or frame type structure) which extends from the frame of a fabric dispensing device between the purlin spacings in a direction opposite that of the direction of the dispensing of fabric i.e. typically towards the worker/installer. Such a cantilever, in addition to supporting the roofing fabric sheet as it is being dispensed from a roll, also serves as a means to prevent a worker from falling through that particular space (between two adjacent purlins) within which a particular cantilever is extending. Such a cantilever achieves effective fall protection, but only at the location where the cantilever happens to be located (i.e. at the time of the fall). In addition, such a cantilever structure is rather large and cumbersome and adds considerably to the weight and cost of the roof fabric dispensing device.




Installation of fabric, in general, can also be expensive when it requires extensive pre-preparation (i.e. machine setup) because of the large size of certain known devices used to install the rolled fabric. Further, these known devices are often difficult to install, are designed to operate only in one direction along the length of a purlin, or must be detached and reattached through a cumbersome process when the tensioning device (which biases the roofing fabric roll against the purlin) reaches a purlin cross support. Further time and expense is added when additional, cumbersome equipment must then be added for fall protection.




In view of the above, it is apparent that there exists a need in the art for a rolled fabric dispensing apparatus which overcomes the above drawbacks and which, in certain embodiments, provides a fall protection system which conforms to OSHA standards and yet is easy to employ without additional time and expense. It is a purpose of this invention to fulfill this need in the art, as well as other needs which will become apparent to the skilled artisan once given the following disclosure.




SUMMARY OF INVENTION




Generally speaking, this invention fulfills the above-described needs in the art by providing: a rolled fabric dispensing device for applying a sheet of fabric from a roll of fabric across a surface of a building structure comprised of at least one pair of longitudinally extending substantially parallel structural members, the rolled fabric dispensing device comprising:




a frame member;




means for rotatably supporting a fabric roll;




means for biasing against a surface of a fabric roll thereby to selectively prevent rotation of a fabric roll when a roll is being supported by the means for rotatably supporting a fabric roll;




means for moveably supporting the rolled fabric dispensing device on a surface of a building structure; and




means for preventing reverse travel of the rolled fabric dispensing device on the building structure.




In another embodiment there is provided: a rolled fabric dispensing device for applying a sheet of fabric from a roll of fabric across a surface of a building structure comprised of at least one pair of longitudinally extending substantially parallel structural members, the rolled fabric dispensing device being capable of securing a first end of the sheet of fabric such that when a second, opposite end of the sheet of fabric is secured by sufficient means, the sheet is capable of supporting a 400 lb weight dropped from a height of 42 inches, the rolled fabric dispensing device comprising:




a frame member;




means for rotatably supporting a fabric roll;




means for biasing against a surface of a fabric roll thereby to selectively prevent rotation of a fabric roll when a roll is being supported by the means for rotatably supporting a fabric roll;




means for moveably supporting the rolled fabric dispensing device on a surface of a building structure; and




an anti-reverse brake:




wherein the anti-reverse brake and the means for biasing against a surface of a fabric roll, in combination, are capable of securing the first end of the sheet of fabric thereby to form a layer of fabric which, when secured at the second, opposite end, is capable of supporting a 400 pound weight dropped from a height of 42 inches.




In a further embodiment there is provided: a rolled fabric dispensing device for applying a sheet of fabric from a roll of fabric across a surface of a building structure comprised of at least one pair of longitudinally extending substantially parallel structural members, the rolled fabric dispensing device comprising:




a frame member;




a plurality of cylindrical rollers for rotatably supporting a fabric roll;




a brake plate for biasing against a surface of a fabric roll thereby to selectively prevent rotation of a fabric roll when a roll is being supported by the cylindrical rollers;




rollers for moveably supporting the rolled fabric dispensing device on a surface of a building structure; and




an anti-reverse brake for preventing reverse travel of the rolled fabric dispensing device on the building structure.











IN THE DRAWINGS





FIG. 1

is a side plan view illustrating a known rolled fabric dispenser in the prior art as disclosed as prior art in U.S. Pat. No. 6,393,797.





FIG. 1A

is a three-dimensional view of a prior art rolled fabric dispenser as disclosed in U.S. Pat. No. 6,308,489.





FIG. 2

is a three-dimensional view of the prior art dispenser illustrated in

FIG. 1

shown on a typical roof structure.





FIG. 3

is a side plan view of a rolled fabric dispenser according to one embodiment of this invention.





FIG. 4

is a partial, underside view of a rolled fabric dispenser according to one embodiment of this invention.





FIG. 4A

is an alternative embodiment of the rolled fabric dispenser illustrated in FIG.


4


.





FIG. 5

is a side plan view of another embodiment of the rolled fabric dispenser according to this invention.





FIG. 5A

is an alternative embodiment of the rolled fabric dispenser illustrated in FIG.


5


.





FIG. 6

is a three-dimensional view of the embodiment illustrated in FIG.


5


.





FIG. 6A

is a three-dimensional view of an alternative embodiment of the rolled fabric dispenser illustrated in FIG.


6


.





FIG. 7

is a top view of the embodiment of

FIG. 6

shown in combination with a fabric roll on a roof structure.





FIG. 8

is a partial underside view of an embodiment of an optional stabilizing clamp according to the subject invention.





FIG. 9

is a partial three-dimensional view of an embodiment of the fall protection system according to the subject invention.





FIG. 10

is a side plan view of an optional extension device constituting a part of an embodiment of this invention.











DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS





FIGS. 1

,


1


A and


2


(prior art) illustrate two known and rather successfully used, commercial dispensers


100


and


100


′ for applying a roll of fabric


90


, such as high-density, woven-polyethylene, over purlins in a roof system. Generally speaking, commercial dispenser


100


includes frame member


104


, guide


106


for embracing the top flange of a purlin (or girt)


6


with a minimum amount of friction, and fabric roll retaining means


108


for retaining a roll of fabric


90


against the surface of the flanges of purlins


6


. Provided as a means for biasing the roll against the purlin flanges onto which the sheet


91


of fabric is applied (with or without adhesive or adhesive tape first being applied) is tensioning device


110


. Through its biasing spring, adjustable by wing nut


114


, the entire device


100


is secured to the upper surface of the purlin flange via a glide roller


102


, upwardly biased by the coil spring against the undersurface of the flange. For convenience, only purlin


6


and cross support member


70


are shown in FIG.


1


.





FIG. 1A

is an improved commercialized embodiment of the dispenser in

FIG. 1

currently in successful use. Its two principal improvements are its ability to be easily adapted to either a right or a left extending purlin flange via its “H” shaped construction at


80


′,


82


′,


83


′ and its low profile plate


30


′ which allows for continuous dispensing despite the presence of purlin cross-members


70


′.




As illustrated in

FIG. 2

, the typical roof structure


2


experienced in practice, normally includes a plurality of parallel purlins


6


, as well as cross support members


70


. As shown in

FIG. 1

, purlins


6


are conventionally “Z” shaped in cross section and include a vertical web portion


10


, which connects a top flange


8


to a lower flange


12


each of which extends perpendicularly from web portion


10


. Purlins


6


may be installed in the roof structure so as to have their top flanges


8


(for example) oriented in the same or opposite directions. Other purlin types are known however and are contemplated to be within the field of use of the present invention.




When prior art dispenser


100


is employed, and the dispenser is mounted in place on a purlin


6


to dispense fabric


90


, such as is illustrated in

FIG. 1

, tensioning device


110


biases glide wheel


102


against the under surface of top horizontal flange


8


. In turn, this biasing force serves to hold guide


106


and a roll of fabric


90


(via engagement means


108


) firmly against the upper surface of top horizontal flange


8


. In order to dispense the roll of fabric into a sheet


91


extending across the purlins by residing on top of the flanges


8


, push pole


112


, shown inserted in frame


104


, may be used to propel the dispenser


100


along the length of purlin


6


, thereby unrolling fabric


90


onto the upper surface of the roof structure


2


(top flange


8


). A similar function is employed by dispenser


100


′, as can be seen in

FIG. 1A

, whose low profile glide mechanism


30


′ avoids most cross members


70


′ which interfere with continuous operation of dispenser


100


′.




Referring again to

FIG. 2

there is illustrated a typical metal roof structure, generally indicated at


2


. This figure helps demonstrate the problems with dispenser


100


(or


100


′) when faced with such a popular roof structure and further serves to highlight the improvements of the invention herein.




Generally speaking, roof structure


2


, as illustrated, includes rafters


4


which are fixed in a parallel arrangement and extend from one side of the roofing structure


2


to the roof peak as indicated at


5


. In practice, rafters


4


may be spaced as shown or, at other times, more widely spaced. Typically such spacing is approximately 25 feet centerline to centerline with respect to these rafters


4


. Purlins


6


(or in other embodiments, bar joists) are fixedly attached via their lower horizontal flange


12


to, and on top of, rafters


4


in a perpendicular configuration. They are normally spaced at a distance of five feet (centerline to centerline) in a substantially parallel fashion. At times, of course, other spacing is employed. In addition, the top horizontal flanges


8


of the purlins


6


do not always extend in the same direction. In some cases, for example, purlins


6


may be installed with the top horizontal flanges


8


extending both towards and away from the roof peak


5


(e.g. both right and left in relation to the forward direction the dispenser takes when dispensing the fabric, see

FIG. 1A

at


6


′ and


8


′). Cross support members (i.e. bracing members)


70


(or


70


′) are provided and are attached to adjacent vertical web portions


10


of purlins


6


(spanning the distance between two parallel purlins) to provide additional strength to the roofing structure


2


.




The use of cross support members


70


presents the problem referred to above, which is associated with dispenser


100


and which is overcome by dispenser


200


of this invention and dispenser


100


′ of FIG.


1


A. As shown best in

FIG. 1

, wheel


102


of prior art dispenser


100


comes into interfering, obstructing, contact with cross support member


70


during the dispensing process. This necessitates the disengagement of dispenser


100


each time a cross support member


70


is reached. The magnitude of this problem is heightened by the generally time consuming and cumbersome fashion of the disengagement process. As can be seen, each time the dispenser


100


is to be mounted or removed to or from a purlin, wing nut


114


must be adjusted (i.e. threaded upwardly) a sufficient distance to allow the large glide wheel


102


to be removed from under flange


8


, including its lip


8




a,


and then readjusted after clearing the cross member, to the proper tension, each time a cross member obstructs the path of the dispenser. Moreover, as another problem, each time a purlin flange extends in a different direction, the device must be started in a different direction or another device having the glide member on the other side of frame member


104


put into service.




As can be seen in

FIG. 1A

, both of these problems are overcome by my prior art device through the use of a low profile mechanism


30


′ and an “H” shaped tubular configuration at


80


′,


81


′,


82


′ and


83


′ which allows the changing of plate member


30


′, and its accompanying spring construction, from side A to side B as desired.




Both of these problems are, also again, solved by the subject invention through the use of a unique dispenser structure which will be described in greater detail in the paragraphs that follow. Generally speaking however, and with particular reference to

FIGS. 3-10

, a unique dispenser


200


is provided which is capable of dispensing along the full length of a purlin


6


without the need for removal upon encountering a cross support member


70


and which is also capable of dispensing in any direction along the length of a purlin irrespective of the orientation of the purlin top flange


8


. In addition, dispenser


200


is capable of locking itself in a desired position on a roof surface and of preventing undesired unrolling of fabric from rolls


90


.




Referring still to

FIGS. 3-10

, dispenser


200


generally includes a frame


203


and associated elements capable of retaining a roll of fabric


90


as well as enabling dispenser


200


to travel smoothly and unencumbered along the length of roof purlins or other analogous building elements regardless of the presence of cross members


70


in the roof structure. Still further, certain other elements are provided which are capable of locking dispenser


200


to a purlin at a desired location thereon.




More specifically, and with particular reference to

FIG. 3

, frame


203


has attached thereto a sub-frame


213


which includes two sets of arms


209


and


211


, each set being provided for supporting a single rotatable metal cylinder (i.e. cylindrical rollers


205


and


207


). In particular, dispenser


200


carries rolls of fabric (i.e. fabric roll


90


not shown in

FIG. 3

for convenience) upon these cylinders where they are relatively free to rotate during the fabric dispensing operation. In the embodiment as illustrated, arm set


211


extends to a height greater than that of arms


209


. This serves to elevate roller


207


above the height of roller


205


and thus aids in retaining fabric roll


90


within the dispenser (because it is difficult to pull a fabric roll


90


over the additional height of roller


207


).




To secure roll


90


within dispenser


200


(see FIG.


5


), and further to selectively secure roll


90


against unwanted rotation (and thus against undesired unrolling of fabric), biasing brake plate


217


is provided. Brake plate


217


is preferably of a generally arcuate shape and is pivotally attached to frame


203


via pivotable arm


215


. In order to bias brake plate


217


against a roll of fabric (via arm


215


) being carried, tension spring


243


is provided and is attached to arm


215


at one end and to a location proximal frame


203


at its other end. Arm


215


is pivotable, of course, so that brake plate


217


is capable of maintaining continuous contact with roll of fabric


90


even as the fabric roll becomes smaller as fabric is dispensed. In addition, this pivoting feature permits relatively easy loading and unloading of fabric rolls as will be described below.




As aforesaid, brake plate


217


is biased against fabric roll


90


(

FIG. 5

) via tension spring


243


which, in the illustrated embodiment, is attached at one end to frame


203


and at its opposite end to arm


215


. Also optionally provided is a serrated plate


219


attached to the undersurface of brake plate


217


. In particular, plate


219


is provided to increase the amount of friction between the surfaces of the fabric roll


90


and the brake plate


217


thereby to maximize the ability of brake plate


217


to control the rotation of a fabric roll.




Although plate


219


may be composed of any known material or combination of materials, examples of such plates may be formed from molded rubber, plastic, textured cloth, or any other material suitable for supplying friction. Specifically, this added friction (as between a fabric roll


90


and brake plate


217


) helps prevent fabric roll


90


from unrolling when not desired (e.g. such as might otherwise occur if high winds were present at a jobsite).




In certain exemplary embodiments, one such embodiment being illustrated in

FIG. 6A

, two brake plates i.e. brake plates


217


and


218


are provided in order to hold (i.e. bias against) fabric roll


90


in a more secure fashion. Such an embodiment provides more contact surface area between the brake plates (


217


and


218


) and roll


90


and thus, of course, imparts more friction to the surface of roll


90


for greater holding power.




In certain further embodiments, rollers


205


and


207


are mounted in particularly desirous locations so that they are spaced a distance from each other which is less than that of the distance of the outside diameter of the typically cardboard core of the fabric roll being used (see FIG.


5


). Since the outside diameter of the core of roll


90


is usually approximately 5 inches, a typical spacing for rollers


205


and


207


is approximately 4 inches (ie. the distance between the two rollers as mounted on sub-frame member


213


is approximately 4 inches). In particular, this specific spacing of rollers


205


and


207


prevents fabric roll


90


from falling between the rollers as roll


90


becomes smaller as fabric is dispensed (ie. as sheet


91


).




It is contemplated, of course, that any number of rollers can be used (spaced at any variety of distances) in practicing the subject invention, the primary purpose being merely to rotatably support fabric roll


90


as fabric is being dispensed.




In still further alternative embodiments of the subject invention, rollers


205


and


207


may be replaced by an elongated and generally arcuate metal sheet which is welded or mechanically fastened (or otherwise fixedly attached) to frame member


203


. The shape of such an arcuate sheet should be such that it can accommodate a variety of roll sizes yet will continue to carry a roll of fabric


90


and allow it to rotate therein as the roll size decreases during dispensing.




In order for dispenser


200


to travel easily along a surface of a roof structure, two rollers


221


and


223


are provided mounted at the front and the rear of the structure of the dispenser (see, for example, FIGS.


3


and


6


). In the illustrated embodiment, these rollers are of conventional type such as rollers typically used on boat trailers. In the alternative, these rollers may be of any design, material, or construction so long as they permit dispenser


200


to be readily advanced along a roof surface. In this respect, roller


223


may be mounted by conventional means proximal the front of frame


203


with roller


221


mounted by similar means towards the rear of dispenser


200


and proximal sub-frame


213


. Specifically, the use of rollers


221


and


223


solves one of the problems of the prior art discussed herein. In particular, because these rollers support dispenser


200


by rolling on top of a purlin (i.e. on the upper surface of a purlin top flange), no cross support member


70


is in the path of the rollers, and hence, the dispenser can travel the entire length of a roof structure without having to be removed. Still further, because rollers


221


and


223


do not interact with or rely on any particular orientation of purlin flange


8


, dispenser


200


may dispense in any direction along any given purlin.




In the process of fabric dispensing, it is desirable that a dispenser, such as dispenser


200


, be capable of maintaining itself in a desired (e.g. forward) position on a roof surface and not have a tendency to reverse in direction i.e. opposite that of dispensing. For example, winds or other forces may catch the fabric sheet


91


(being dispensed from fabric roll


90


) and tend to pull the fabric dispenser from its desired location or position on a roof surface (i.e. in the direction reverse of dispensing). Therefore, optionally provided in the present invention is an anti-reverse brake structure


220


which prevents dispenser


200


from being drawn backwards in a direction opposite that of the intended direction of dispensing. Such a brake structure also serves as an integral part of the fall protection system which is described in detail below.




Referring in particular now to

FIG. 4

, one embodiment of anti-reverse brake structure


220


is illustrated and is generally comprised of two metal cylinders


225


and


227


which, as shown, are eccentrically mounted (i.e. mounted off-center) in a pivotable manner to shafts


229


and


231


respectively. Preferably, these cylinders have a granular outer surface (i.e. surfaces


226




a


and


226




b


) for better gripping and thus better anti-reverse holding power. In order to retain cylinders


225


and


227


at a relatively fixed location (about shafts


229


and


231


) when the dispenser is at rest, two springs


233


and


235


are provided which are attached to each cylinder respectively and to a common location


237


at cross bar


241


. Normally, if cylinders


225


and


227


are caused to rotate about shafts


229


and


231


, springs


233


and


235


will tend to pull or return these cylinders back to their original position. Granular outer surfaces


226




a


and


226




b


may, of course, be substituted for by any material capable of gripping a suitable surface of a purlin.




Also, albeit optionally, located proximal the outside walls of cylinders


225


and


227


are cylinder engagement rods


230


and


232


which serve to restrict the rotational movement of cylinders


225


and


227


about shafts


229


and


231


. In particular, cylinder engagement rods


230


and


232


are simply provided so that cylinders


225


and


227


are always oriented with a slight rearward angle of rotation against the force of springs


233


and


235


prior to dispenser


200


being mounted upon a purlin


6


.




In still a further alternative embodiment of anti-reverse brake structure


220


(illustrated in FIG.


4


A), cross bar


241


is constructed so that its arms may be extended or shortened thereby to increase or decrease the distance between the innermost walls of cylinders


225


and


227


. Cross bar


241


is constructed so as to be adjustable, in this regard, because purlins may be encountered which are not of uniform width. Similarly, it may be desirable to operate dispenser


200


on building elements which are not purlins e.g. such as bar joists. In such situations, arms


241




a


and


241




b


may be simply adjusted by sliding the arms further on or off of the base portion of cross bar


241


thereby to increase or decrease the size of the purlin passageway. After adjusting the arms to the appropriate/desired lengths, arms


241




a


and


241




b


may be effectively locked in position by the use of locking pins


241




c


and


241




d


inserted through apertures (shown illustrated but not numbered) in each as well as in the base portion of cross bar


241


.




When operating an embodiment of dispenser


200


which includes anti-reverse brake structure


220


, a purlin


6


or other roof structural member is disposed between cylinders


225


and


227


. If dispenser


200


is advanced in the typical forward direction (i.e. in the direction of roller


223


), then, as the preferably granular outer walls of cylinders


225


and


227


engage the surface of the purlin


6


, the cylinders will be caused to pivot about their respective shafts


229


and


231


thus releasing the purlin


6


and allowing passage of the purlin


6


therebetween (i.e. by effectively increasing the distance from one cylinder wall to the next because of the rotation of the cylinders in combination with the eccentric mounting arrangement). In effect, as dispenser


200


is moved forward, the cylinder walls rotate away from one another (about shafts


229


and


231


), thus increasing the width of the purlin passageway and allowing the forward advancement of dispenser


200


.




If, however, an attempt is made or a force is imparted which seeks to move dispenser


200


in a direction reverse of dispensing, cylinders


225


and


227


will again be caused to rotate about their eccentric pivot points (i.e. shafts


229


and


231


), but this time in the opposite direction. Because of their eccentric attachment to shafts


229


and


231


, the cylinders will then engage the side surfaces of the purlin (or other building element) with sufficient force to prevent reverse travel of the dispenser. This is because as the cylinders pivot when an attempt is made to move dispenser


200


in a reverse direction, the distance between the two cylinders


225


and


227


decreases (as their walls rotate towards each other) thus effectively closing off the otherwise open passageway. If a continued attempt to move dispenser


200


in a reverse direction is made, the abrasive (granular) walls of cylinders


225


and


227


will simply bite harder into the side surfaces of the purlin


6


. Thus, with the aforedescribed brake structure of the illustrated embodiment, the dispenser is effectively prohibited from being advanced in the wrong direction on the purlins.




It is through the use of this brake structure


220


in combination with the biasable brake plate


217


(and, in some embodiments, optional brake plate


218


) described hereinabove that dispenser


200


is able to complete a safety-net type fall protection system which is able to conform to OSHA standards (see

FIG. 9

) without adding the additional weight and expense of typical of prior art systems.




Specifically, dispenser


200


is able to sufficiently secure a layer of fabric


91


such that the layer is capable of conforming with the OSHA standard of safety net fall protection as enumerated in 29 C.F.R. Section 1926.502c. In particular, in order to conform to this standard, a safety net type fall protection system must be able to withstand the force of a 400 lb weight dropped from a height of at least 42 inches. Further, the weight which is dropped must not have a diameter of greater than 30+/−2 inches. Such tests have been performed on a layer of fabric sheet


91


secured with dispenser


200


with such layer being able to withstand and support the dropped 400 lb weight “W” from a height of at least 42 inches as illustrated as distance “X” in FIG.


9


. It should be noted, of course, that the particular strength of roof fabric which is employed is critical in such a test and that such factors must be taken into account when utilizing the above described system as fall protection. In this regard, the fabric used in the aforementioned tests is a conventional high-density woven polyethylene fabric.




Such a system as disclosed by the present application is able to conform to such a test because of the particular effectiveness of anti-reverse brake structure


220


in securing dispenser


200


at a given location on a purlin


6


(and preventing it from being pulled in a reverse or backwards direction when an object is dropped on the fabric) and further because brake plate


217


(or brake plates


217


and


218


in combination) is particularly effective at preventing the unwanted rotation of fabric roll


90


. It is noted here, of course, that although the leading end of the fabric is secured by dispenser


200


, the trailing end is secured by the conventional installation and securing of the metal sheeting layer “ML” shown in FIG.


9


.




Turning now to one example of a manner of operating the subject invention (both as a dispenser and as a manner of constructing a fall protection system), dispenser


200


may be simply lifted into operating position by placing dispenser


200


so that rollers


223


and


221


are resting on the upper surface of a purlin


6


(or other analogous building element) as shown in FIG.


7


. In this position, cylinders


225


and


227


are located a distance slightly below the horizontal plane of these rollers so that cylinders


225


and


227


will embrace (with the force of springs


233


and


235


) the respective sides of the purlin.




In certain embodiments of the subject invention as illustrated in

FIG. 8

, stabilizing clamp


301


is optionally included to provide further stability to dispenser


200


before a roll


90


is loaded onto the rollers. In the subject embodiment, stabilizing clamp


301


is pivotally mounted to the underside of sub-frame


213


and includes an adjustable stabilizing rod


305


at the end of which a stabilizing plate


303


is fixedly attached. Also attached to sub-frame


213


, parallel to but opposite in orientation to that of adjustable stabilizing plate


303


, is stationary stabilizing plate


309


. Between plates


303


and


309


then, is a space for the passage of a building element i.e. such as a purlin


6


therebetween. In order to operate stabilizing clamp


301


, lever


307


is utilized to shift stabilizing plate


303


into engagement with one side or surface of a purlin


6


while stationary stabilizing plate


309


engages the other side of the purlin. In this manner, dispenser


200


is effectively clamped to the purlin and thus rendered more stable when resting upon the purlins before a fabric roll


90


is loaded thereon.




Once dispenser


200


is in place on the roof structure (and in some embodiments stabilizing clamp


301


is engaged) a roll of fabric


90


may be loaded onto the dispenser. This may be accomplished by merely lifting brake plate


217


(and arm


215


) against the force of tension spring


243


. In one embodiment of the subject invention, brake plate


217


may be locked in place in the open position utilizing a locking bar


251


(see FIGS.


6


and


6


A). Locking bar


251


is simply a metal rod with angularly extending portions at each end which is rotatably attached substantially parallel to arm


215


via conventional brackets. Once brake plate


217


(and arm


215


) is lifted a sufficient distance against the force of spring


243


, the brake plate may be locked in place in the open position by simply rotating locking bar end


251


′ into engagement with locking plate


249


. Once end


251


′ is in engagement with locking plate


249


, brake plate


217


(and in some embodiments plate


218


) and arm


215


are locked in the open/roll loading position against the force of spring


243


. At this time a fabric roll


90


may simply be placed upon rollers


205


and


207


and brake plate


217


and arm


215


released (via the release of end


251


′ of locking bar


251


). Once this is done, brake plate


217


should be in engagement with fabric roll


90


. At this time it is also appropriate to release stabilizing clamp


301


(i.e. by operating the toggle lever


307


to the open position) in preparation for dispensing.




Thereafter, in order to begin the roof fabric dispensing process at one end/side of the building structure, the loose or trailing end of fabric roll


90


is initially unrolled and secured (e.g. by adhesive tape) to the end purlin (or rake angle) located at the end/side of the building from which the dispensing is to commence. In order that an initial portion of fabric


90


be more easily unrolled, brake plate


217


may be manually lifted to release braking pressure on the fabric roll. The entire apparatus may then be pushed forward, utilizing push pole


253


as shown in

FIG. 9

, to dispense fabric as sheet


91


. As dispenser


200


is pushed forward, it simply rolls along the top surface of purlin


6


on rollers


221


and


223


. In order to insure that push pole


253


may be easily reached (i.e. is at a reachable height) angular adapter


255


is provided which simply inserts into an opening of frame member


203


(see FIGS.


9


and


10


). Push pole


253


may then be inserted into the opposite end of adapter


255


thus angling push pole


253


to a much lower height.




In a preferred embodiment of the subject invention illustrated in

FIGS. 5

,


6


, and


6


A, there may be (optionally) provided an arm structure


247


and associated padded cylindrical roller


245


so located and attached to frame member


203


such that it is capable of biasing fabric sheet


91


against a surface of the roof structure as the sheet is dispensed (to insure that fabric is laid out in a substantially flat manner). In particular, arm


247


is pivotally attached to frame


203


(so it may be lifted out of the way in order to load a fabric roll


90


and will adjust as roll


90


becomes smaller) and is of sufficient weight in combination with padded roller


245


to passively bias fabric sheet


91


(via gravity) against a surface of the roof structure without need for external forces. However, it is contemplated that in some alternative embodiments, it may be desirable to employ a spring or other device to provide an active biasing force.




In still another embodiment (FIG.


5


), locking plate


248


is provided which may be positioned in place, such as by the tightening of wing nut


250


, for example, against flange


247


′ located on arm


247


, during the dispensing of fabric when arm


247


is in contact with fabric sheet


91


(i.e. in the “biasing” position). When locking plate


248


is oriented as illustrated (against flange


247


′), locking plate


248


holds arm


247


securely against the surface of the fabric sheet


91


even during strong winds or other disruptive forces.




In yet even a further embodiment (illustrated in FIG.


5


A), a retaining hook


214


is provided which is, in one embodiment, pivotally attached (via pivot


216


) to or proximal to sub-frame


213


. Retaining hook


214


is provided so that it may be positioned under a surface of purlin top flange


8


. Thus, if a disruptive force is applied to dispenser


200


(such as by an object dropped on sheet


91


as the sheet is being dispensed), the retaining structure will aid in securing dispenser


200


on the purlin (by its contact with the undersurface of purlin flange


8


).




During operation (ie. during rolled fabric dispensing) then, rather than biasing fabric roll


90


against a surface of purlins


6


(as in prior art devices), dispenser


200


includes a unique structure by which fabric roll


90


is supported/carried above (ie. not in contact with) purlins


6


. In utilizing this unique carrying structure, which is not limited in the length of a roll which it can carry, dispenser


200


is pushed (e.g. via push pole


253


) along the length of a building structure, and fabric is pulled (ie. dispensed) from fabric roll


90


to form fabric sheet or layer


91


. In this manner, fabric layer


91


is installed across the entire length of the building to complete a vapor retarding barrier in the insulated roof structure.




As hereinabove described, some exemplar dispensers of the subject invention are capable of securing fabric sheet


91


sufficiently well that the layer formed by sheet


91


(as it is dispensed by certain embodiments of dispenser


200


) is capable of conforming to the OSHA standard for safety-net type fall protection enumerated at 29 C.F.R. Section 1926.502c. In particular, once the first or starting end of the fabric is secured at the beginning of the roof structure (e.g. at the rake angle), such as by metal screws or adhesive tape or glue, for example, the first section of roof is installed, as aforedescribed, by unrolling at least a first layer of insulation and thereafter placing the metal sheeting layer on top of the layer of insulation. Once the metal sheeting layer ML is in place (see FIG.


9


), this layer is fixed by screws or other conventional means. It is at the completion of this first layer that the trailing end of the fabric sheet


91


first becomes sufficiently secured to comply with specific OSHA requirements. Thereafter, each additionally installed section of roof will continues to secure fabric sheet


91


as the installation progresses across the top of the building structure.




Still further, it is contemplated that in utilizing certain embodiments of the present invention, fabric sheet


91


may be anchored such that the sheet is capable of supporting the weight of installed insulation batts without need for other mechanical supports (e.g. banding, straps, or cantilevers) such as are used in certain known prior art roofing systems. Even further, during fabric installation with the present invention, in certain embodiments there will be no need to secure fabric sheet


91


to the surface of the purlins with adhesive or other means (except at the starting end). In this respect, fabric sheet


91


may be anchored sufficiently in place (tight or with drape) utilizing the braking capabilities of unique dispenser


200


to support the weight of subsequently installed insulation (the system as a whole thereafter being secured in place when the metal roof or other type sheeting is secured to the purlins with sheet screws or other conventional means). In like fashion, the dispensers of the subject invention are capable of securing fabric sheet


91


against wind and/or other disruptive weather types.




Although the particular order of installing the elements of roof sections as described herein is generally conventional in nature, it is the use of unique dispenser


200


which enables the practice of the subject invention as a fall protection system which, in this respect, conforms to OSHA standard 29 C.F.R. Section 1926.502c when properly used. This OSHA standard is incorporated herein by reference.




In particular, as aforesaid, brake plate


217


(or multiple brake plates


217


and


218


) in combination with anti-reverse brake structure


220


secure the leading end of the fabric sheet


91


i.e by securing roll


90


at a fixed location and against rotation. This provides a relatively taut layer of fabric


91


which is able to withstand and support (as required by the aforesaid OSHA standard), a 400 lb weight “W” dropped from a height of at least 42 inches (the height indicated as distance “X” in FIG.


9


). Such a layer does not, of course, protect an installer from falling from the side of a roof structure, nor does it protect an installer from falling through any area not covered by the layer of fabric i.e. such as the area ahead or in front of the dispenser


200


as fabric is being unrolled over the roof structure. Therefore, it is required that at all times supplemental fall protection, such as harnesses and/or railings always should be used to protect workers in those areas. In this respect, however, this invention constitutes a significant step forward in the safety art by replacing the heretofore cumbersome cantilever equipment etc. with a sheet of plastic which is a part of the roof system itself.




In certain further embodiments of this invention, when multiple. dispensers are being employed such as illustrated in

FIG. 9

, multiple chains


259


(as seen in

FIG. 5

) may be attached at aperture


257


to link each dispenser


200


. When linked, if a dispenser falls from a purlin, this safety feature may, at times, prevent the dislodged dispenser from falling to the ground (because the dispenser is attached to the other dispensers which are anchored in place and because the chain will catch on the purlins which extend between the multiple dispensers


200


).




Finally, in dispensing fabric, the dispensers of this invention may be employed to form the sheets in a variety of configurations such as stretched tightly (laterally) across purlins


6


or in a draped fashion between the purlins such as is taught in my co-pending U.S. patent application Ser. No. 09/511,306, filed Feb. 23, 2000 and entitled ROLLED FABRIC DISPENSING METHOD, now U.S. Pat. No. 6,393,797, the disclosure of which is incorporated herein by reference.




Once given the above disclosure, many other features, modifications, and improvements will become apparent to the skilled artisan. Such other features, modifications, and improvements are therefore considered to be part of this invention, the scope of which is to be determined by the following claims.



Claims
  • 1. A rolled fabric dispensing device for applying a sheet of fabric from a roll of fabric across a surface of a building structure, the rolled fabric dispensing device comprising a frame member and an anti-reverse brake, said anti-reverse brake including:a first and a second shaft located proximal said frame member; a first and a second cylinder each spaced from the other and each eccentrically mounted to said first and said second shaft in a manner to permit pivotal movement of said cylinders about an axis of said shafts; a first spring attached proximal said frame member and to said first cylinder; a second spring attached proximal said frame member and to said second cylinder; wherein a distance between said first and said second cylinder defines a space for passage of a building element therebetween.
  • 2. The rolled fabric dispensing device according to claim 1, wherein said anti-reverse brake further includes a cylinder engagement rod so located proximal a surface of a said cylinder so as to orient said cylinder at an angle of rotation against the force of said spring attached to said cylinder.
  • 3. The rolled fabric dispensing device according to claim 1, which further includes means for rotatably supporting said roll of fabric and means for selectively preventing rotation of said roll of fabric when supported on said supporting means.
  • 4. The rolled fabric dispensing device according to claim 3, wherein said means for selectively preventing rotation of said roll of fabric comprises:a first arm member having a first and a second end, said first end pivotally attached to said frame member; a first plate member attached proximal said second end of said first arm member in a manner which allows it to be selectively brought into and out of engagement with said roll of fabric; and a spring attached between said first arm member and said frame member so located as to provide a biasing force to said plate member in the direction of said roll of fabric.
  • 5. The rolled fabric dispensing device according to claim 4, wherein said means for selectively preventing rotation of said roll of fabric further includes:a second arm member having first and second ends attached to said second end of said first arm member; and a second plate member for contacting a surface of a fabric roll; wherein said first plate member is attached to said first end of said second arm member and said second plate member is attached to said second end of said second arm member.
  • 6. The rolled fabric dispensing device according to claim 5, wherein said first and said second plate members each including an arcuate surface comprising a friction plate so located as to contact said roll of fabric when said plate member is selectively brought into contact with said roll of fabric.
  • 7. The rolled fabric dispensing device according to claim 1, further including a fabric sheet biasing mechanism comprising:an arm structure pivotally attached to said frame member; and a biasing member attached proximal an end of said arm structure and capable of biasing a fabric sheet against a surface of a building structure as the fabric sheet is dispensed from a roll of fabric.
  • 8. The rolled fabric dispensing device according to claim 7, further including a locking mechanism for locking said fabric sheet biasing mechanism in a biasing position comprising:a locking bar; a flange plate positioned to selectively engage said locking bar; and wherein said locking bar is so constructed as to be rotatable into engagement with said flange plate to secure said biasing member against a surface of a fabric sheet.
  • 9. The rolled fabric dispensing device according to claim 8, further including a retaining hook pivotally attached to a frame member of said dispenser and so located as to be positionable under the surface of a roof structural member for securing said dispenser to roof member.
  • 10. The rolled fabric dispensing device according to claim 1, which further includes a first cylindrical roller and a second cylindrical roller so spaced and located as to form a support for said roll of fabric.
  • 11. The rolled fabric dispensing device according to claim 10, wherein said first and second cylindrical rollers are so located within said dispenser such that said second roller is located at a higher elevation with respect to said first roller and wherein said second roller is the rearward most roller with respect to the direction of dispensing of said fabric.
  • 12. The rolled fabric dispensing device according to claim 1, which further includes a first and a second roller for contact with a surface of a building structure.
  • 13. A rolled fabric dispensing device for applying a sheet of fabric from a roll of fabric across a space in a building structure between at least one pair of spaced longitudinally extending substantially parallel structural members, said rolled fabric dispensing device being capable of securing a first end of said sheet of fabric such that when a second, opposite end of said sheet of fabric is secured, said sheet is capable of supporting a 400 lb. weight dropped from a height of 42 inches, the rolled fabric dispensing device comprising the device of claim 1, 2, 3, 4, 5, 6, 9, or 11.
  • 14. A method of fabricating an insulated roof structure of a building which includes at least one pair of longitudinally spaced and substantially parallel structural members, the method comprising:securing a first end of said roof fabric; locating a second end of said roof fabric within the roof fabric dispensing device of claim 1; moving said dispensing device along said pair of spaced longitudinally extending, substantially parallel structural members to dispense a sheet of said roof fabric across the space between said pair of structural members such that said sheet of said fabric so dispensed and extending across said space provides fall protection across said space during said dispensing of said sheet of roof fabric across said space.
  • 15. The method of claim 14, wherein said sheet of roof fabric located across said space during said dispensing thereof is capable of supporting a 400 lb. weight dropped from a height of 42 inches.
  • 16. The method of claim 15, wherein said roof fabric is dispensed from a fabric roll and wherein said fabric roll is of a length which spans at least three spaced purlins.
  • 17. The method of claim 15, wherein said roof fabric is comprised of polyethylene.
  • 18. The method of claim 17, wherein said roof fabric consists essentially of a high-density, woven polyethylene fabric.
  • 19. A rolled fabric dispensing device for applying a sheet of fabric from a roll of fabric across a surface of a building structure comprised of at least one pair of spaced, longitudinally extending substantially parallel structural members, the rolled fabric dispensing device comprising:a frame member; means for rotatably supporting a fabric roll; and a mechanism for creating a biasing force against a surface of said fabric roll which includes: a first arm member having a first and a second end, said first end being pivotally attached to said frame member; a second arm member having first and second ends, said second arm member being attached to said second end of said first arm member; a first brake plate and a second brake plate spaced from said first brake plate, said first and second brake plates each being connected to said second arm member; and a spring so located and connected between said first arm member and said frame member so as to bias said brake plate against a surface of a fabric roll.
  • 20. The rolled fabric dispensing device according to claim 19, wherein said first and said second brake plates comprise a generally arcuate surface and a friction plate attached to said arcuate surface for contact with said fabric roll.
RELATED APPLICATIONS

This application is the non-provisional application of U.S. Provisional Application No. 60/243,276 filed Oct. 26, 2000, invented by Gary E. Romes, and upon which the present application relies for priority.

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Provisional Applications (1)
Number Date Country
60/243276 Oct 2000 US