Not applicable.
Not applicable.
Not applicable.
Not applicable.
This document generally relates to the field of roofing and devices used therein for stabilizing roofing ladders on roof surfaces and additionally, includes a safety mechanism for workers in case of slipping or falling as well as anchors for holding tools.
Asphalt roof shingles currently represent 80% of the residential roof market in the United States today. They vary in style, colors, and sizes and will continue to do so. They have a limited lifespan and are designed to be replaced multiple times during the life of the structure or home they are protecting. They are easily damaged by falling branches, hail, and often by homeowners, painters, satellite dish installers, chimney workers, and even roofers. Sometimes, the damage, in the form of holes, tears or punctures, are intentionally done by these contractors while installing communication equipment such as antennas and satellite dishes, roof jacks, ladder support brackets and roof safety equipment. Examples of such ladder support brackets and safety equipment are disclosed in U.S. Patent application No. 2004/0135037 A1, U.S. Patent Application No. 2007/0278037 A1 and U.S. Pat. No. 5,896,719. The installation of these devices often requires the installer to drill or puncture holes through the asphalt shingles to drive anchors into the rafters or wood sheathing beneath the shingle layers in order to secure the ladder support brackets or safety equipment to the roof. These anchors may include large common nails or screws. After the roofing job is completed and the ladder support brackets, roof jacks and safety equipment are removed, any holes, tears, or punctures must be repaired to prevent water leaks through the shingles and into the interior of the building. Regardless of how the shingles are damaged, current methods of repairing such holes, tears, or punctures simply include coating and/or filling the holes or punctures with conventional roofing cement or sealant. Although such methods have proven to be satisfactory in the short term, they are costly, time consuming, messy, unattractive and distracting from the original beauty of the shingle. If done improperly the entire hole, tear or puncture may not be completely filled and sealed and the leak will continue. And even when done properly, these methods generally fail within 7 years due to exposure to sunlight and the cyclic hot and cold temperatures which crack or dislodge this type of repair. This becomes a repeating nuisance, leak and expense for the homeowner who might have 30 years of life remaining for their shingles. If the damage is too extensive, the shingles may need to be replaced entirely, which may lead into other problems such as matching the shingles with currently available shingles or finding an available experienced repair person. Such methods require other tools such as an injecting/caulking gun and tube of sealant, or a spatula for spreading the cement or sealant from a pale of cement.
As a solution to this problem, an asphalt shingle sealing device as disclosed in copending patent application Ser. No. 14/808,195 eliminates any of the drawbacks of the current repairing methods discussed supra. The asphalt shingle sealing device relates generally to an asphalt roof shingle sealing device comprised of a single flat blank sheet of metal or rigid plastic. The asphalt shingle sealing device includes a simple, non-messy, quick and easy-to-use asphalt shingle sealing device that eliminates the need to inject or coat roofing cement or sealant into the holes, tears or punctures as employed in the current methods.
In performing roofing jobs such as those described supra, other dangers exist. According to OSHA, falls in the workplace are the leading cause of injury and death. In 2013, 294 deaths occurred by falls in construction and lack of proper fall protection in construction was number one in citations.
OSHA requires the use of Personal Protective Equipment (PPE) while working at heights that put someone at risk of falling more than 6 feet. Working on roofs is very dangerous and ridge anchor points for fall protection devices are a critical component of the PPE system. OSHA does not, however, tell workers “how” they can safely reach the ridge of a roof to install a proper anchor (because that's been a real problem up until the bracket of the present invention was invented). OSHA acknowledges this difficulty by allowing roof inspectors to climb about on roofs, unprotected by fall protection equipment as long as anchors or proper fall protection equipment is installed prior to “work” actually beginning. The installer of the first anchor point has also been waived from this requirement.
Thus, the question remains: How can workers get to the ridge of a roof safely so they can install a first safety ridge anchor or another first safety anchor device? Thus, there is a need in the industry to address this problem.
The present invention, as described in detail hereinafter, provides a solution to the problem by including a bracket having a ladder clamping mechanism and safety mechanism to which a worker's safety equipment can be attached. The bracket of the present invention may be installed easily and quickly on asphalt, cedar shake or slate roofs by a competent person. The present invention may also be adaptable to metal roofs by using a conversion bracket as discussed hereinafter. Depending on the extent of the roof, several brackets of the present invention may need to be installed on the roof. A first bracket is installed on the roof near a peripheral eve thereof by a worker standing on a ladder leaning against the edge of the roof. After the first bracket is mounted to the roof, another ladder is then raised onto the roof and inserted into the bracket and clamped in place. The worker can then attach his/her safety equipment to the bracket or ladder and safely mount the ladder lying on the roof. As the worker climbs the ladder, other brackets may be installed on the roof for further securement of the ladder holding the worker for another ladder. These other ladders may be installed in line with the previous ladder, or may be installed in side-by-side relation. Depending on the extent of the roof, the worker could then install other brackets for holding ladders or providing additional anchor points for fall protection as necessary until the ridge is reached.
The present invention, as described in detail hereinafter, provides a solution to the problem by including a bracket having each part made of a rigid and suitable material that meets the required strength to hold the ladder, a worker, and the impact load of a vertical fall of six feet by the worker as required to be OSHA compliant. The bracket could be made from sheet metals such as mild steel, stainless steel, or aluminum. The sheet metal preferably is in the range of 10-12 gauge. The bracket could be made from moldable metals by injection or pour molding processes. Other moldable materials such as strong polymers or carbon fiber materials could also be employed from which the bracket is molded. The present invention is not to be limited by the materials selected in its manufacture as long as they meet OSHA requirements. The bracket includes a ladder rung clamping mechanism for securing a ladder to the roof of a building and safety mechanism to which a worker's safety equipment can be attached.
The bracket of the present invention includes a flat base member having a bottom surface adapted to overly the roof and a top surface. The base member having an upper end adapted to be mounted facing the ridge of the roof and a lower end with a first part of the clamping mechanism extending from the lower end of the base member and adapted to secure the rung of a ladder therein. The upper end includes a width and a length with at least one hole and/or side slot therein for receiving anchors such as 20 penny nails, lag bolts or ledger lock bolts that are driven or screwed through the asphalt shingle, slate, or cedar shake and into roofing substrate and roof rafter to secure the base member to the roof. The lower end of the base member includes a width and a length and a series of centrally located holes therethrough that are either threaded or not threaded for receiving anchor bolts therethrough from the bottom surface of the base member. Such anchor bolts are recessed into the bottom surface of the base member so as to be flush with the bottom surface and thereby prevent any damage to the underlying shingles. The first part of the clamping mechanism comprises an extension of the base member that is configured as a J-shaped cross-section to act as a hook in which the rung of a ladder is nested.
In a first embodiment, the J-shaped cross-section of the first part of the clamping mechanism extends across the entire width of the lower end of the base member. The J-shaped cross-section is formed by a first bend extending a first portion of the base member extension approximately 90 degrees with respect to the plane of the remaining base member and a second bend extending a second portion of the base member extension in the same direction as the first portion at an obtuse angle of approximately 55 degrees with respect to the plane of the first portion or 145 degrees with respect to the plane of the remaining base member. The second bend is spaced from the first bend a distance Z, Z′ to surround a ladder rung or approximately 2-3 inches. The first embodiment also includes a flat elongated spacer bar having a bottom surface adapted to overly the top surface of the base member and a top surface. The spacer bar includes an upper end and a lower end. The lower end of the spacer bar is configured as a safety attachment member. The spacer bar member preferably has a width and length less than the width and length of the base member and is adapted to overly the base member along the central axis thereof. However, the dimensions of the spacer bar is not intended to be limiting and can vary. The safety attachment member is angled upward from the plane of the flat spacer bar at approximately 30 degrees and includes a hole for receiving an attachment of a safety gear and/or tethered tool of a worker. The first portion of the J-shaped cross-section includes a central opening through which the safety attachment member extends. The spacer bar also includes stop elements extending laterally from the lower end and adapted to abut the first portion of the J-shaped cross-section to prevent the safety attachment member from passing through the central opening. The upper end of the spacer bar includes a series of holes aligned with holes in the lower end of the base member, whereby when safety attachment member is inserted onto the base member and secured thereto such as by welding or bolting, the safety attachment member extends outwardly of the lower end of the base member for a worker to attach safety gear thereto such as a safety lanyard. The first embodiment further includes a second part of the clamping mechanism comprised of materials similar or the same as the base member and includes a clamping member having a bottom surface adapted to overly the top surface of the spacer bar and a top surface. The clamping member having an upper end adapted to overly the upper end of the spacer bar and a lower end adapted to overly the lower end of the spacer bar. Although not intended to be a limitation of the shape and dimensions of the clamping member and base member, the widths of the upper ends of the clamping member and base member may be approximately equal, and the lower end of the clamping member may be approximately equal to the lower end of the base member. The upper end of the clamping member includes a centrally longitudinally extending slot therein disposed to be in alignment with the aligned holes in the upper end of the spacer bar and base member. The clamping member further includes a clamping extension extending from the lower end of the clamping member. The clamping extension extends across the entire width of the lower end of the clamping member and is formed by a first bend extending a first portion of the clamping extension at an obtuse angle of approximately 110 degrees with respect to the plane of the clamping member and a second bend extending a second portion of the clamping extension in an opposite direction to the first bend at an obtuse angle with respect to the plane of the first portion such that the second portion is approximately parallel with the plane of the clamping member thereby forming an S-shaped cross-section. The second bend of the clamping extension is spaced from the first bend a distance to surround a ladder rung or approximately 2-3 inches. The second portion of the clamping extension having a pair of laterally spaced apart tabs extending therefrom in the plane of the second portion. Each tab having a hole extending therethrough for receiving an attachment of a safety gear and/or tethered tool of a worker. The second portion of the J-shaped cross-section of the base member having a pair of laterally spaced holes therethrough disposed to be in alignment with the laterally spaced tabs of the clamping member such that as the clamping member is mounted to the base member, the rung of a ladder is captured between the J-shaped cross-section of the base member and the S-shaped cross-section of the clamping extension of the clamping member with the spaced tabs extending through the laterally spaced holes. The clamping member is secured to the base member either by bolts passing through the slot into holes of the spacer bar and into the threaded holes in the base member, or by nut and bolt fasteners passing through the slot from aligned holes in the base member and spacer bar. The clamping member may also be secured by through bolts or screws passing through the slot and clearance holes in the spacer bar and base member and into the roof itself.
In a second embodiment of the present invention, the base member and clamping members are similar to those of the first embodiment with the exception that the length X′ of the upper end of the base member is somewhat shortened and may have fewer slots and holes. This embodiment also does not include a safety attachment member. Furthermore, the first portion of the J-shaped cross-section does not include a central opening. Instead, a flat elongated spacer bar is used having a lower end abutting against the first portion of the J-shaped cross-section. As in the first embodiment, the spacer bar includes a series of centrally located holes aligned with the holes in the lower end of the base member. Each tab having a hole extending therethrough to which a worker's safety equipment and/or a worker's tethered tool can be attached.
In a third embodiment of the present invention, the upper end of the base member is similar to the upper end of the base members of the second embodiments. In this embodiment, the upper end of the base member is somewhat shortened and includes a width and a length with at least one hole and/or side slot therein for receiving anchors such as 20 penny nails, lag bolts or ledger lock bolts that are driven or screwed through the asphalt shingles, slates or cedar shakes and into roofing substrate and roof rafter to secure the base member to the roof. This embodiment does not include a spacer bar or a separate safety attachment member as in the first or second embodiments. The lower end of the base member, first part of the clamping mechanism and safety attachment member and are formed as a one-piece structure. The clamping member is the same as in the first and second embodiments. The first part of the clamping mechanism is formed by two J-shaped cross-sections extending from opposite ends of the lower end of the base member. These J-shaped cross-sections are configured similar to the J-shaped cross-sections of the first and second embodiments. Each J-shaped cross-section includes first and second portions configured just as in the first and second embodiments. Each second portion of each J-shaped cross-section includes an opening disposed to be in alignment with the tabs of the clamping member for receiving the tabs of the clamping member when it is attached to the base member. In this third embodiment, the safety attachment member is disposed between the two J-shaped sections and is formed as an extension of the lower end of the base member and is bent out of the plane of the base member at an angle of approximately 30 degrees. The safety attachment member includes an opening therethrough for receiving a connecting device for a worker's safety equipment and/or a worker's tethered tool. The clamping member is secured directly to the base member in the same manner as disclosed in the first and second embodiments.
The figures included herein are various views of the structures and installations of the first, second and third embodiments of the present invention. Although the figures depict exact dimensions of the preferred embodiments, such dimensions may be varied and therefore, not to be considered limiting.
Referring to
As illustrated in
In the first embodiment, the J-shaped cross-section of the first part of the clamping mechanism extends across the entire width of the lower end of the base member. The J-shaped cross-section is formed by a first bend (17) extending a first portion (18) of the base member extension approximately 90 degrees with respect to the plane of the remaining base member (1) and a second bend (19) extending a second portion (16) of the base member extension in the same direction as the first portion (18) and at an obtuse angle of approximately 55 degrees with respect to the plane of the first portion (18). The second bend of the base member extension is spaced from the first bend a distance Z approximately 2.0-3.0 inches to fit around a conventional ladder rung which is approximately 1.5-2.0 inches. The first embodiment also includes a flat elongated spacer bar (2) having a bottom surface (20) adapted to overly the top surface (10) of the base member and a top surface (21). The spacer bar includes an upper end (22) and a lower end (23). The lower end of the spacer bar is configured as a safety attachment member (24). The spacer bar member may have a width and length less than the width and length of the base member and is adapted to overly the base member along the central axis thereof. However, these dimensions are preferred and not intended to be limiting and may vary. The safety attachment member (24) may be angled upward at 24′ from the plane of the flat spacer bar at an angle θ (
As illustrated in
As best illustrated in
As illustrated in
As illustrated in
Referring to
The converter bracket is designed to be mounted to a conventional metal roof having flat metal sections bound by vertically extending standing seams. The converter bracket includes a base plate for lying flat against the metal roof between the standing seams and may be approximately 12-16 inches in width. The length of the converter bracket may vary depending on which embodiment of the present invention is used and may be approximately 10-20 inches in length. The base plate further includes side flanges extending laterally therefrom. Each side flange includes a first segment (57) extending normally to the base plate and a second segment (58) extending laterally from the first segment. Each side flange preferably may extend the length of the base plate or may be comprised of several sections. Each first segment (57) having a height approximately equal to the height of a conventional metal roof standing seam anchor (55), such as those disclosed in U.S. Pat. Nos. D629,679 or 8,756,870, incorporated herein by reference. Each second segment (58) includes a series of holes for receiving lugs extending from each seam anchor (55) for securing the converter bracket against the metal roof. The base member of the converter bracket also includes a series of centrally located upstanding threaded studs 60 attached thereto such as by welding to which any of the slots or holes in the first, second or third embodiments can be mounted.
The present invention has been described supra in terms of various embodiments and as set forth in the detailed illustrations in the attached figures. It will be appreciated by those skilled in the art that various changes and modifications may be made to the embodiments without departing from the spirit or scope of the invention. It is not intended that the invention be limited to the embodiments shown and described. It is intended that the invention include all foreseeable modifications to the embodiments shown and described. It is intended that the invention be limited in scope only by the claims appended hereto.
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Number | Date | Country | |
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20160130876 A1 | May 2016 | US |
Number | Date | Country | |
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62075982 | Nov 2014 | US |