Patent Grant
11268288
This invention relates to modular scaffolding systems that are erected as impermanent structures to support platforms, and in particular to improve horizontal scaffold members used in these modular scaffold systems. Scaffolding is used, inter alfa, in the industrial, commercial, petro-chemical, power source, general industry and residential construction markets.
In 2008, the Bureau of Labor Statistics' Census of Fatal Occupational Injuries (CFOI) reported 88 fatalities and many more non-fatal injuries occurred in the year 2007 related to the use of scaffolds. Twenty-seven percent (27%) of the fatalities, and many of the injuries, involved falls from over 25 feet high during the installation of welded frame scaffolds. Safety officials recommend that scaffolding falls be pre-empted through the use of sequential erection techniques. This involves installing guardrails and standards at regular distances along the scaffold such that the exposed platform edge is not greater than a bay length between intervals. The use of safety harnesses or belts tethered to guardrails during the erection process is also a recommended safety practice. However, the use of safety harnesses to deter fall injuries during scaffold erection is quite limited due to the components used in conventional scaffolds. The nature and design of conventional scaffold components, as described herein, disadvantageously do not allow the effective use of safety harnesses during the erection process.
Tube and coupler scaffolds are so-named because they are built from tubing connected by coupling devices. Due to their strength, they are frequently used where heavy loads need to be carried, or where multiple platforms must reach several stories high. Components of scaffolds include vertical standards having coupling rings or rosettes, horizontal components such as ledgers and guardrails coupled to the coupling rings or rosettes, footings, decks/platforms and diagonal braces. Their versatility, which enables them to be assembled in multiple directions in a variety of settings, also makes them difficult to build correctly.
Conventional scaffolding systems have various components.
Referring now to
Referring to
Referring now to
Duel trigger connectors also have been developed to increase the safety of prior art scaffold systems. Examples include those shown and described in U.S. Pat. Nos. 8,881,869 and 9,303,417, both of which are incorporated by reference. These devices are designed to allow a single installer to insert and lock pivoting wedges at both ends of the horizontal member, and to release both ends substantially simultaneously if using the primary trigger, or to only release one end if using the secondary trigger. The two triggers are coupled by a cable, in a configuration where (1) pulling on the primary trigger releases the associated latch member and pulls the cable taunt, thus pulling and disengaging the secondary trigger and releasing its associated latch member, and (2) pulling on the secondary trigger releases the associated latch member but loosens the cable, thus leaving the primary trigger undisturbed and cable loosens the cable, thus leaving the primary trigger undisturbed and the associated latch member engaged. However, the primary latch may be disengaged inadvertently, an undesired result.
Referring now to
Still referring to
A cable 700 (rope, chain or other flexible connector, but generally not substantially stretchable lengthwise, with a preferred embodiment being a ⅛ inch wire rope) runs through the hollow interior of the horizontal member 600. One end of cable 700 enters the interior of the primary wedge head 601p, and slides over a member 90p, such as a pin, pulley or other member, which may be rotatable in the wedge head interior. The cable 700 then extends downwardly and is attached to or is connected to the wedge assembly at the handle 611p. The other end of the cable 700 enters the interior of the secondary wedge head 601s (or secondary end connector 390), and slides over member 90s and then is connected to or attached to the wedge assembly at wedge 612. The members 90a and 90B may be dispensed with, but they are preferred to keep the cable 700 from binding in the respective wedge head 601. As shown, a first end of the cable 700 is connected to the trigger portion 611p in the primary wedge head 601p; while the second end of the cable 700 is connected to the wedge portion 612s in the secondary wedge head 601s. As a result, as the trigger portion 611p in the primary end connector 490 is depressed and pivoted downwardly (thereby unlatching the wedge portion 612p head in the primary connector), the cable 700 follows the trigger portion 611p downwardly. As a result, the wedge portion 612s in the secondary connector 390 is also pivoted or pulled away from the corresponding vertical member 800, and the connected trigger portion 611s compresses the respective spring 620s, thereby pivoting the secondary wedge head assembly 610s, against the spring bias, to the unlatched position. In this fashion, a single operator may thereby unlatch both wedge heads by the operation of only the primary trigger portion 611p. Operation of the primary trigger or handle on the primary end connector exerts a force on the secondary end connector to detach the secondary end connector from the second vertical member simultaneously with the detachment of the primary end connector from the first vertical member. When actuated, the primary trigger transmits force through a cable tension cable. As the cable is drawn downward in the primary connector, the other end of the cable is drawn toward the primary end connector by the tension in the cable. As the wedge is connected to the cable, the wedge is thus drawn to the unlatched position. Contra wise, as the secondary latch is dawn downward to unlatch the secondary connector, the cable's tension is lessened on the primary connector, and hence no forced is exerted to counterbalance the tension of the spring in the primary end connector. However, if the operator operates the secondary trigger portion 611s on the secondary end connector 390 to open or unlatch the secondary wedge portion 612s by depressing the secondary trigger portion 611s and pivoting the handle downwardly, such action will not open or unlatch the wedge portion 612p on the primary end connector 490. This occurs due to the different attachment points of the cable 700 to the primary and secondary wedge assemblies 610. The act of operating the secondary trigger portion 611s will not result in the spring 620p in the primary wedge head 610 being compressed as there is no force exerted on the primary spring in response to operation of the secondary trigger portion 611s in the secondary connector 390. As the secondary trigger portion 611s is drawn downward to unlatch the secondary connector 390, the cable's tension is lessened on the primary connector 490, and hence no forced is exerted to counterbalance the tension of the spring in the primary end connector. Preferably, the two trigger portions 611p and 611s are shaped differently (not shown) so that an operator may easily distinguish the primary end connector from the secondary end connector. An alternative embodiment of a prior art, dual-trigger latching connector is shown in
Referring now to
An inspection of the foregoing prior art, dual-trigger connectors shows that: (1) pulling on the primary trigger releases the associated latch member and pulls the cable taunt, thus pulling and disengaging the secondary trigger and releasing its associated latch member; and (2) pulling on the secondary trigger releases the associated latch member but loosens the cable, thus leaving the primary trigger undisturbed and the associated latch member engaged. Consequently, these prior art devices are designed to allow a single installer to release both ends of a horizontal scaffold member substantially simultaneously if using the primary trigger, or to only release one end if using the secondary trigger. However, with each of these prior art devices, the primary latch may be disengaged inadvertently, which is an undesired result.
The invention disclosed herein is generally directed to a scaffold system having a horizontal scaffold member featuring primary, secondary, and tertiary release triggers which collectively allow a user to simultaneously connect and disconnect the ends of the horizontal member to a vertical member of the scaffold system while also preventing inadvertent disconnection of the horizontal member.
A scaffold system exemplifying the principles of the present invention can comprise a horizontal scaffold member having a primary end connector and a secondary end connector. Each end connector is configured to couple to an annular member—such as a cup or rosette—on a vertical scaffold member. Each end connector includes a wedge assembly having a trigger (e.g., a handle) and a wedge movable between a latched and unlatched position. The primary end connector includes two triggers, a first or primary trigger that is connected to—and actuates—the primary wedge head, and a tertiary trigger or handle that is not connected to the primary wedge head, but is connected, such as by cable, to the secondary handle and wedge head. The primary handle may be actuated separately from the tertiary handle, or may be actuated in conjunction with the tertiary handle. The design is an improvement over prior art designs using the primary handle to disconnect both ends simultaneously. The improved design provides a disconnect of the original primary trigger from the cable, and therefore allows a user to operate the primary trigger only for connecting or disconnecting he primary end from the scaffold vertical. The ability to disconnect both the primary and secondary ends remains by operation of the tertiary or third trigger, in combination with the primary trigger. The secondary end of the horizontal remains independently disconnectable, independent from the cable system, by operation of the secondary trigger or handle. This improvement prevents inadvertent actuation of the secondary trigger, and release of the second end, when operating the primary trigger. This improvement gives the user a choice to operate/actuate the secondary trigger when needed from the primary end by engaging the tertiary trigger while operating the primary trigger, or to just release the primary end by actuating only the primary trigger. Preferably, the tertiary trigger will be colored in a contrasting color to help the user identify the third trigger, and further his or her understanding of the use of this system and the triggers functions.
In further embodiments, components of the scaffold system of the present invention may include at least one horizontal member comprising a horizontal tube having a primary end connector and a secondary end connector attached at opposing ends of the tube. Each end connector (also sometimes referred to herein as a “wedge head”) may include: i) an upper engagement portion that is designed to engage the top portion of an annular ring on a vertical scaffold member; and ii) a wedge portion that is designed to releasably engage the bottom portion of the annular ring, thereby securing the horizontal member to the vertical member when the end connector is positioned adjacent to the vertical member's annular ring(s). Preferably, each vertical member has at least one annular ring—such as cup or rosette—affixed thereto. More preferably, each vertical member has a plurality of annular rings in coaxial alignment thereon. In embodiments utilizing a cup, the cup has an upper side and an underside, with the upper side of the cup preferably having an upstanding edge or lip engaged by the upper engagement portion of the end connector. In certain embodiments, the upper engagement portion of the end connector may take the form of a hook, a projecting finger, a tooth or cutout located on the upper portion of the end connector. In preferred embodiments, each end connector has upper and lower engagement portions formed in the sidewalls of the end connector, with the upper engagement portion adapted to engage an upper annular ring of the vertical member and the lower engagement portion adapted to engage a lower annular ring of the vertical member. However, the invention is not limited to embodiments having two or more engagement sections, and can be utilized on scaffold systems where the end connectors are connectable to a single annular ring (such as a single cup or rosette).
In yet further embodiments, the vertical and/or horizontal members are hollow tubes constructed of metal, preferably galvanized metal of about ⅛ inch thickness. The end connectors each can be a crimped metal tube having an interior section, with suitable openings to accommodate the wedge assembly. The end connectors may be attached at substantially right angles to the long axis of the horizontal tube, or the end connectors may compromise two substantially parallel sidewalls (suitably joined together for rigidity) and having an interior space there between, and also joined to the horizontal tube at substantially right angles to the long axis of the horizontal tube.
A more complete understanding of the invention may be obtained by reference to the following Detailed Description, when taken in conjunction with the accompanying Drawings, wherein:
Detailed embodiments of the present invention are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the invention. While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.
As used herein, the terms “a” or “an” are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “comprises,” “comprising,” or any other variation thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. The terms “including,” “having,” or “featuring,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. As used herein, the term “about” or “approximately” applies to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. Relational terms such as first and second, upper and lower, top and bottom, right and left, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions.
Referring to
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In one embodiment, the cable 1101 is pivotally attached to the tertiary trigger 3000 above the top of the trigger 3000 at a pivoting point 3003 (
In operation, to release the primary end of the horizontal end connector from a vertical scaffold member, the primary trigger 1104 alone is grasped and rotated downwardly, thereby moving only the coupled wedge head assembly and wedge 1104B away for the rosette or cup, allowing removal of the primary end connector 1106 from the vertical scaffold member by exerting an upward force. In this instance, the secondary end of the horizontal scaffold member (containing the secondary trigger 1103) remains connected to an adjacent vertical scaffold member. However, if both the primary trigger 1104 and tertiary triggers 3000 are actuated together (pivoted downwardly), both the primary and secondary triggers, and the associated primary wedge 1104B and secondary wedge 1103B, are moved to an unlatched or unlocked configuration, allowing for complete removal of the horizontal scaffold member from the two adjacent vertical scaffold members, by application of an upward force.
Preferably, the tertiary trigger 3000 is colored differently (e.g., red) from the primary trigger to help an operator visually distinguish the tertiary trigger from the primary trigger. Additionally, the tertiary trigger may have a lock to keep the trigger from actuation. For instance, a flexible spring button may to located on the sidewall of the join to interact with an opening on the tertiary trigger, such as opening 3030 shown in
Other embodiments of the tertiary trigger are possible. For instance, the tertiary trigger 3000 may have be a single flat plate-like member connected to the cable, with the plate mounted above the primary trigger. Alternatively, a single plate tertiary trigger may be mounted adjacent to one side of the primary trigger, allowing the primary trigger to be actuated alone, the primary and tertiary triggers to be actuated simultaneously, or the tertiary trigger to be operated alone. To assist in a tertiary trigger alone operation, the single bar may have a hand or finger grip or ring attached thereto (not shown). Alternatively, the cable may end in a connector, such as a loop, or a spring snap link can be connected, or disconnected to a connector attached to the primary connector (like an eyebolt). In this embodiment, a tertiary trigger is not needed; to activate just the primary wedge assembly with the primary trigger, the cable is disconnected to the primary trigger before activation; to activate both wedge assemblies with the primary trigger, the cable is connected to the primary trigger before activation of the primary trigger.
In an embodiment of the invention, the design of the end connector at each end of each horizontal member keeps scaffold components square and rigid at all times utilizing predetermined angles via the grid design. The scaffold design of the invention reduces leading edge fall hazards associated with conventional scaffold systems. The scaffold design of the invention also reduces the need for hand tools during the installation and dismantling of horizontal members. Advantageously, the scaffold design of the invention reduces the amount of labor and time needed to install and dismantle a scaffold system.
The components of the invention can be fabricated from a variety of materials, including galvanized or powder coated steel, iron or other resilient material. The rosette preferably has a seven inch (7″) diameter, and the internal first and second rods can comprise two square, or cylindrical rods, made of e.g., steel or iron, each having a wedge portion added or integrated at an end, the opposite ends being coupled to the crank/cam assembly. Using the grid pattern of apertures on the rosette and head having prongs dimensioned to fit therein, various angles between the horizontal members can be obtained (e.g., 45, 90, 180 degrees) for the elevated working platform.
Advantageously, the invention allows the erector to engage and disengage both wedge portions of a single horizontal member from a single point reducing installation time and creating a safer work environment. This is because the primary and tertiary triggers, may be simultaneously activated by a single operator, to engage and disengage each wedge substantially simultaneously. In this manner, up to eight (8) horizontal members can be attached to a single vertical member by a single installer without changing his position.
The invention further comprises a grid of components that mesh together creating rigid angled connection among a plurality of horizontal members at a vertical member. Both of the wedges which are part of a wedge assembly, are locked into position at the rosette on a vertical member from a single position. The internal wedge portions are locked into place by an external handle eliminating the use of any hand tools. The external handle can also be locked into place creating a secondary locking device.
The embodiments shown and described above are only exemplary. Even though numerous characteristics and advantages of embodiments of the invention have been set forth in the foregoing description together with details of the invention, the disclosure is illustrative only and changes may be made within the principles of the invention to the full extent indicated by the broad general meaning of the terms used herein. For example, the concepts described herein for coupling horizontal members to vertical members can be used to couple bracing members to vertical members or to horizontal members. Coupling includes, but is not limited to attaching, engaging, mounting, clamping, welding, bolting and components used for coupling include bolts and nuts, rivets, clevis, latches, clamps, welds, screws, rivets and the like. Further, a rosette having eight (8) radially arranged cut-outs is described herein for illustrative purposes and a rosette having more or less radially arranged cut-outs is considered to be within the scope of this invention. Also, the invention describes a rosette having a standard diameter of about seven (7) inches, however, any suitable diameter can be used. The use of a wedge head with a pair, or a wedge head with two pair, of vertical prongs is described herein for illustrative purposes and a wedge head having one or more prongs is considered within the scope of this invention. The rosette can include any suitable cut-out shape that is dimensioned to receive a corresponding prong or set of prongs of a wedge head. The vertical member can have any number of coaxially aligned rosettes attached thereto, the vertical spacing of such rosettes being any such distance as is suitable for the intended use. More generally, the invention is a scaffold system with a horizontal member, a vertical member with at least one rosette affixed in coaxial alignment to the vertical member and a wedge assembly within the horizontal member, portions of the wedge assembly for locking the horizontal member to the rosette. The vertical member has a plurality of evenly spaced rosettes affixed in coaxial alignment along the vertical member and at least one rosette has a pattern or grid of apertures designed to receive the end of the horizontal member.
To those skilled in the art to which this invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined herein and in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. The embodiments shown and described above are only exemplary. Even though numerous characteristics and advantages of embodiments of the invention have been set forth in the foregoing description together with details of the invention, the disclosure is illustrative only and changes may be made within the principles of the invention to the full extent indicated by the broad general meaning of the terms used herein. For example, the concepts described herein for coupling horizontal members to vertical members can be used to couple bracing members to vertical members or to horizontal members. Coupling includes, but is not limited to attaching, engaging, mounting, clamping, welding, bolting and components used for coupling include bolts and nuts, rivets, clevis, latches, clamps, welds, screws, rivets and the like. The vertical member can have any number of coaxially cups attached thereto, the vertical spacing of such cups being any such distance as is suitable for the intended use. The method includes a method of disconnecting both ends of a horizontal scaffold member from a vertical scaffold member.
This application claims priority to U.S. Provisional Application Ser. No. 62/655,337 filed on Apr. 10, 2018, which is incorporated by reference herein in its entirety.
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| Number | Date | Country | |
|---|---|---|---|
| 20190330864 A1 | Oct 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 62655337 | Apr 2018 | US |
| Child | 16380399 | US |
