US20230151620A1 - Multi-Function Scaffold with Reversible Platform - Google Patents
Multi-Function Scaffold with Reversible Platform Download PDFInfo
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- US20230151620A1 US20230151620A1 US18/097,349 US202318097349A US2023151620A1 US 20230151620 A1 US20230151620 A1 US 20230151620A1 US 202318097349 A US202318097349 A US 202318097349A US 2023151620 A1 US2023151620 A1 US 2023151620A1
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- vertical support
- side rail
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G1/00—Scaffolds primarily resting on the ground
- E04G1/18—Scaffolds primarily resting on the ground adjustable in height
- E04G1/20—Scaffolds comprising upright members and provision for supporting cross-members or platforms at different positions therealong
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G1/00—Scaffolds primarily resting on the ground
- E04G1/14—Comprising essentially pre-assembled two-dimensional frame-like elements, e.g. of rods in L- or H-shape, with or without bracing
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G1/00—Scaffolds primarily resting on the ground
- E04G1/28—Scaffolds primarily resting on the ground designed to provide support only at a low height
- E04G1/30—Ladder scaffolds
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G5/00—Component parts or accessories for scaffolds
- E04G5/02—Scaffold feet, e.g. with arrangements for adjustment
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G5/00—Component parts or accessories for scaffolds
- E04G5/08—Scaffold boards or planks
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G5/00—Component parts or accessories for scaffolds
- E04G5/16—Struts or stiffening rods, e.g. diagonal rods
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G7/00—Connections between parts of the scaffold
- E04G7/02—Connections between parts of the scaffold with separate coupling elements
- E04G7/28—Clips or connections for securing boards
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G1/00—Scaffolds primarily resting on the ground
- E04G1/24—Scaffolds primarily resting on the ground comprising essentially special base constructions; comprising essentially special ground-engaging parts, e.g. inclined struts, wheels
- E04G2001/242—Scaffolds movable on wheels or tracks
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G1/00—Scaffolds primarily resting on the ground
- E04G1/28—Scaffolds primarily resting on the ground designed to provide support only at a low height
- E04G1/30—Ladder scaffolds
- E04G2001/302—Ladder scaffolds with ladders supporting the platform
- E04G2001/305—The ladders being vertical and perpendicular to the platform
Definitions
- the present disclosure relates generally to lightweight scaffolding and, more particularly, to a lightweight, multi-function scaffold with a reversible platform.
- Lightweight scaffolds made from metal tubing are commercially available for use when working close to the ground.
- One such scaffold comprises an adjustable height platform supported between two ladder frames.
- the platform includes two side rails with guide channels at each end that slide up and down along the vertical supports of the ladder frames. Casters insert into the lower ends of the vertical supports so that the scaffold can roll on the floor or other support surface.
- the scaffolds are configured to be stacked vertically. Stability of the scaffold is provided by a braces that connect the guide channels to the platform.
- the design of lightweight scaffold involves a trade-off between the height adjustment range and stability.
- Lightweight scaffolds tend to be less stable than typical heavy-duty scaffolding. Stability can be increased in two ways: by reducing the amount of play between the vertical supports of the ladder frame and the guide channel makes, and by reducing the flex of the ladder frame at the upper end of the adjustment range. Increasing the length of the guide channels at the ends of the side rails achieves both of these stability enhancements.
- While increasing the guide channel length provides greater stability, it comes at the cost of significantly less adjustment range.
- the movement of the guide channels that slide along the legs is limited by interference with other components of the scaffolding. For example, when the platform is lowered, the guide channels may come into contact with other components. Because the guide channels extend down from the platform, the interference with other components establishes a lower limit on the platform height. Reducing the length of the guide channel would enable the platform to be lowered closer to the ground but would make the scaffolding less stable. Therefore, the length of the guide channels for lightweight scaffolding currently on the market compromises the adjustment range in order to improve stability.
- the present disclosure provides a lightweight scaffold designed to provide a greater range of height adjustment while at the same time greatly increasing stability. Greater stability is achieved in by increasing the length of the guide channels. Greater range of height adjustment is achieved by making the platform reversible so that it can be mounted between the ladder frames in either a first orientation or in a second orientation. Making the platform reversible increases the range of height adjustment in two ways. First, orienting the platform so that the guide channels extend in an upward direction allows the platform to be lowered closer to the ground than conventional designs. When the platform is oriented with the guide channels extending downwardly, the increased length enables the platform to be raised above an upper end of the ladder frame while maintaining stability. The stability can be enhanced by properly clamping the guide channel to the vertical supports of the ladder frame to remove play between the guide channels and the vertical supports.
- the caster or other ground engaging member includes a stem that inserts into the lower end of the vertical supports and is secured by a span pin that passes through aligned openings in the vertical support and in the stem of the caster.
- the guide channel cannot extend below the span pin so the span pin limits the range of movement.
- an opening is provided in the guide channel that aligns with the openings in the vertical support and caster stem when the platform is lowered to a predetermined height. The addition of the opening allows the platform to be lowered below the span pin to further increase the adjustment range.
- FIG. 1 is a perspective view of a scaffold including two ladder frames and an adjustable height platform according to one exemplary embodiment.
- FIG. 2 A is a side view of the scaffold with the platform adjusted to a top of the ladder frame. In some embodiments, this is the maximum height.
- FIG. 2 B is a side view of the scaffold with the platform adjusted to a height above the top end of the ladder frame.
- FIG. 3 is a side view of the scaffold with the platform adjusted to minimum height.
- FIG. 4 A is a partial perspective view of a side rail and guide channel for the adjustable height platform.
- FIG. 4 B is partial perspective view of a side rail and guide channel for the adjustable height platform with the platform extending above the height of the ladder frame.
- FIGS. 5 A and 5 B are cross section views of exemplary side rails for the adjustable height platform.
- FIG. 6 is a partial top plan view of the platform showing a locking mechanism to secure the deck to the side rails of the adjustable height platform.
- FIG. 7 illustrates compact stacking of two ladder frames for shipment or storage.
- FIG. 8 is an exploded perspective view illustrating a first method of mounting a caster to the scaffold.
- FIG. 8 A is a perspective view illustrating an alternate method for mounting the caster to the scaffold
- FIG. 9 is an exploded perspective view of a stacking pin for the scaffold.
- FIG. 10 schematically illustrates the adjustment range of the adjustable height platform.
- FIG. 11 illustrates a method of adjusting the height of the platform for the scaffold.
- FIG. 12 shows a perspective view of an alternative embodiment of a side rail assembly with a curved brace.
- FIG. 13 shows a cross-sectional view of the side rail of FIG. 12 taken along XIII-XIII.
- FIG. 14 shows a partial perspective view of a scaffold using the side rail assembly of FIG. 12 , with the side rail in the second orientation for adjustment of the platform to a minimum height.
- FIG. 1 illustrates a multi-purpose scaffold 10 according to an exemplary embodiment.
- the multi-purpose scaffold 10 comprises two ladder frames 12 and an adjustable height platform 20 supported between the two ladder frames 12 .
- the side rails 22 of the adjustable height platform 20 can be mounted between the ladder frames 12 in two different orientations depending on a height requirement for a task.
- the first orientation enables the platform 20 to be adjusted to its maximum height.
- the second orientation enables the platform 20 to be adjusted to its minimum height.
- the adjustment range is between a maximum height of about 78.5 inches and a minimum height of about 10 inches providing an adjustment range of 68.5 inches.
- the maximum height for conventional lightweight scaffolds of this type is about 71 inches and the minimum height for conventional lightweight scaffolds is about 27 inches providing an adjustment range of only 44 inches.
- the design enhancement yield a 55% increase in the adjustment range.
- the first orientation is for relatively greater heights, i.e., farther from the ground, and the second orientation is for relatively lower heights, i.e., closer to the ground.
- Each ladder frame 12 comprises two vertical supports 14 connected by two or more cross members 16 .
- the vertical supports 14 and cross members 16 are preferably made of a metal tubing or other tubular material.
- the cross members 16 are preferably welded at each end to respective ones of the vertical supports 14 so that each ladder frame 12 is a unitary structure.
- the vertical supports 14 have a square or rectangular cross-section and the cross members 16 have a circular cross-section.
- the outside diameter of the cross members 16 is less than the width of the vertical support 14 .
- the cross members 16 can be offset from the center of the vertical supports 14 and the ends of the cross members 16 can be crimped or compressed to facilitate more compact stacking as shown in FIG. 7 .
- a series of aligned openings 18 extend through the vertical supports 14 perpendicular to the plane of the ladder frame 12 and are spaced 2 inches apart. As will be hereinafter described in more detail, the openings 18 are engaged by a releasable locking mechanism 30 on the platform 20 to secure the platform 20 at a desired height between the ladder frames 12 . Additionally, openings 18 a extend transversely through the lower end of each vertical support 14 . These opening 18 a are used to secure casters 50 to the vertical supports 14 when the side rail 22 is in the lowermost position as will be hereinafter described.
- the platform 20 comprises two side rail assemblies that extend between the ladder frames 12 and a deck 40 that is supported by the side rail assemblies.
- Each side rail assembly comprises a side rail 22 and two guide channels 24 at opposing ends of the side rail 22 .
- the side rails 22 are configured to provide a support surface for the deck 40 in both a first orientation and a second orientation.
- Two variations of the side rail 22 are shown in FIGS. 5 A and 5 B respectively. In both cases, the cross section of the side rail 22 is symmetrical about a horizontal plane H.
- the side rail 22 comprises a generally C-shaped channel with a central web 22 a two parallel flanges 22 b .
- Stiffening flanges 22 c extend outwardly from the outer ends of the parallel flanges 22 b .
- one parallel flange 22 b provides a support surface for the deck 40 in a first orientation and the other provides a support surface for the deck 40 in the second orientation.
- the stiffening flanges 22 c and the parallel flanges 22 b form upper and lower bounded notches that include the support surfaces for the first and second orientations, respectively, and these bounded notches are disposed inward relative to the stiffening elements in the form of flanges 22 c .
- the side rail 22 comprises a generally C-shaped channel with a central web 22 a and two parallel flanges 22 b as previously described with two additional channels 22 d attached to the outer ends of the parallel flanges 22 b .
- the parallel flanges 22 b function as support surfaces for the deck 40 in the first and second orientations respectively.
- the channels 22 d and the parallel flanges 22 b form upper and lower bounded notches that include the support surfaces for the first and second orientations, respectively, and these bounded notches are disposed inward relative to the stiffening elements in the form of the channels 22 d .
- the additional channels 22 d provide greater strength and rigidity compared to the design in FIG. 5 A .
- the side rails 22 are equipped with internal latches 42 to hold the deck 40 down once the deck 40 is put in place.
- the latches 42 are mounted to the parallel flanges 22 b of the side rail 22 and are configured to project up through slots 40 a ( FIG. 6 ) in the deck 40 .
- the latches 42 include a catch element 42 a connected to a spring-biased latch pin 42 b that pulls the catch element 42 a down into contact with the top surface of the deck 40 .
- the latch pin 42 b with the attached catch element 42 a is rotatable.
- latch pin 42 b and attached catch element 42 a are rotated so that the catch element 42 a can pass through the slot 40 a in the deck 40 while the deck 40 is being lowered into place.
- latch pin 42 b is pushed upward and then rotated so that the catch element 42 engages the upper surface of the deck 40 as shown in FIG. 6 .
- the latch pin 42 b is biased by a spring 42 c so that when the latch pin 42 b is released, the catch element 42 b presses the deck 40 down against the support surface, thus preventing the deck 40 from lifting up off the side rail 22 .
- each side rail 22 connect directly or indirectly to a C-shaped guide channel 24 sized to fit around the vertical supports 14 of the ladder frames 12 .
- a square sleeve 23 is interposed between each end of the side rail 22 and the guide channel 24 for mounting a safety rail to the platform.
- the sleeve 23 is configured to receive posts P of the safety rail (not shown), which can be secured to the sleeve 23 by locking pins (not shown).
- the side rail 22 , sleeves 23 , and guide channels 24 for each side rail assembly are welded together to form a unitary structure.
- the guide channels 24 comprises a C-shaped channel and are configured to slide along the vertical supports 14 of the ladder frames 12 at each end of the scaffold 10 to adjust the height of the platform 20 .
- Two openings 26 are formed in the inner flanges of each guide channel 24 for locking the guide channel 24 at a selected height as hereinafter described.
- the openings 26 are spaced to align with the openings 18 in the vertical supports 14 of the ladder frame 12 at preselected heights.
- the openings 26 in the guide channels 24 are engaged by a releasable locking mechanism 30 (described below) on the platform 20 to secure the platform 20 at a desired height between the ladder frames 12 .
- a third opening 28 is formed near a lower end of the guide channel 24 and aligns with an opening 18 in the vertical support 14 .
- a locking pin 29 passes through aligned opening 28 and 18 in the guide channel 24 and vertical support 14 respectively.
- the locking pin 29 serves as a failsafe and provides additional safety in case the locking mechanism 30 inadvertently disengages.
- Diagonal braces 25 connect a lower end of each guide channel 24 to the side rail 22 to increase the strength and rigidity of the assembled scaffold 10 . The increased stability enhances worker’s confidence when standing on the scaffold.
- Each guide channel 24 includes a releasable locking mechanism 30 for locking the platform 20 at a desired height.
- the releasable locking mechanism 30 comprises a U-shaped locking pin 32 that engages with the aligned openings 26 and 18 in the guide channel 24 and vertical supports 14 respectively to lock the side rail 22 at a desired height.
- Each locking pin 32 includes a pair of spaced apart legs 32 a connected by a cross member 32 b .
- a bracket 34 supports the locking pin 32 .
- the bracket 34 includes a pair of openings 36 through which the legs 32 a of the locking pin 32 extend.
- Springs 38 surrounding each leg 32 a of the locking pin 32 and bias the locking pin 32 to a locked position. The springs 38 are compressed when the locking pin 32 is pulled back to disengage the locking pin 32 and push the locking pin 32 back to an engaged position when the locking pin 32 is released.
- the guide channel 24 as herein described is increased in length in comparison to prior art designs.
- the increased length enables the platform to be adjusted to a height above the top end of the ladder frames as shown in FIG. 4 B .
- the maximum height for the platform can be increased from about 71 inches to about 78.5 inches.
- the scaffold 10 includes casters 50 disposed at the lower end of each vertical support 14 as shown in FIG. 8 .
- Each caster 50 includes a stem 52 that extends into the lower end of a vertical support 14 .
- the stem 52 is sufficiently long to overlap at least two openings 18 in the lower end of the vertical support 14 .
- the stem 52 of the caster 50 includes an opening 54 that is located to align with an opening 18 in the vertical support 14 when the stem 52 of the caster 50 is inserted into the vertical support 14 .
- a locking pin 56 passes through aligned openings 54 and 18 in the caster 50 and vertical support 14 respectively to secure the caster 50 to the vertical support 14 .
- the stem 52 further includes a second opening 58 oriented 90 degrees relative to the first opening 54 .
- the second opening 58 is for use when the platform 20 is adjusted to the minimum height as shown in FIG. 3 .
- the obstruction of the guide rail 20 prevents insertion of the locking pin 56 through the aligned openings 54 and 18 in the caster 50 and vertical support 14 .
- the second opening 58 aligns with opening 18 a in the vertical support and an opening 27 in the guide channel 24 of the side rail 20 so that the locking pin 56 can be inserted through the aligned openings 58 , 18 a and 27 to secure the caster 50 to the vertical support 14 .
- FIG. 8 A show an alternate embodiment, where the caster 50 includes s single opening 54 as previously described.
- the opening 18 a in the vertical support 14 is vertically aligned with an opening 18 .
- the caster 50 can be turned 90 degrees so that the opening 54 aligns with opening 18 a in the vertical support and the opening 26 in the guide channel 24 of the side rail 20 when the side rail is in the lowermost position as shown in FIG. 3 .
- the casters 50 can be replaced by footpads, level jacks or socket levelers (not shown) or other ground-engaging member. comprising a generally flat pad that contacts the ground or underlying surface and a stem that extends into that extends into the lower end of a vertical support 14 .
- the guide channel 24 cannot extend below the span pin 56 securing the caster 50 or other ground engaging member the lower end of the vertical supports 14 .
- the span pin 56 limits the range of movement at the lower end of the adjustment range.
- an opening 27 is provided at each end of the guide channel 24 that aligns with the openings 18 a and 58 in the vertical support 14 and caster stem 52 respectively when the platform 20 is lowered below the span pin 56 .
- the addition of the openings 27 allows the platform 20 to be lowered below the span pin 56 to further increase the adjustment range.
- the span pin 56 is 2.5 inches above the caster flange. Providing the additional openings 27 in the guide channel allow the platform to be lowered by an additional 2.5 inches plus 1 ⁇ 2 the diameter of the span pin 56 .
- the ladder frames 12 include removable stacking pins 60 at the upper ends of the vertical supports 14 .
- the stacking pins 60 include a threaded end 60 a that screws into an opening 62 a in a mounting block 62 at the upper end of the vertical supports 14 .
- the ability to remove the stacking pins enables more compact packaging for shipments and storage. Additionally, the design enables the use of interchangeable stacking pins of different size and/or shape.
- the scaffold 10 When assembled, the scaffold 10 provides a free-standing, self-supporting structure.
- Outriggers 70 can be used with the scaffold to increase stability by providing a wider base.
- Conventional outriggers 70 for lightweight scaffolds are designed to extend out from the sides of the scaffold in a lateral direction, i.e., perpendicular to the longitudinal axis. This arrangement reduces the risk of tipping sideways but does not improve stability in the longitudinal dimension.
- the multifunction scaffold as herein described provides a greater range of adjustment in the height of the platform 20 .
- the side rails 22 of the platform 20 are mounted between the ladder frames 12 in a first orientation as shown in FIGS. 2 A- 2 B .
- the side rails 22 of the platform 20 are inverted and mounted between the ladder frames 12 in a second orientation as shown in FIG. 3 .
- FIG. 10 is a schematic illustration showing the range of adjustment of the platform 20 in the first and second orientations.
- first orientation is used as a label for the configuration shown in FIGS. 2 A- 2 B and the term second orientation is used a label for the configuration shown in FIG. 3 .
- first orientation the downward movement is limited by the guide channels 24 , which extend downward in this configuration.
- the lower bound of the downward movement is referred to as the first threshold.
- the platform 20 is adjustable to a height between the first threshold and a maximum height.
- the guide channel extends upward and limit the upward movement of the platform 20 .
- the upper bound of the movement is referred to as the second threshold.
- the platform 20 is adjustable to a height between the minimum height and the second threshold.
- FIG. 11 illustrates an exemplary method of configuring the scaffolding for use.
- user determines a height requirement for a particular task (block 110 ). Based on the height requirement, the user selects either the first orientation or the second orientation (block 120 ). If the height requirement is greater than the first threshold, the user can install the platform 20 in the first orientation (block 130 ). If the height requirement is less than the second threshold, the user can install the platform 20 in the second orientation (block 140 ). If the height requirement is greater than the first threshold and less than the second threshold, the user can install the platform 20 in either the first orientation or the second orientation (block 150 ).
- FIG. 12 shows an alternative embodiment of a side rail assembly, with a curved brace 25 .
- the brace 25 is located outwardly laterally offset relative to the flanges 22 b forming the support surfaces for the deck 40 .
- the brace 25 mates to the side rail 22 at the stiffening element, which is located laterally outward (to the left in FIG. 13 ) relative to the corresponding flange 22 b .
- This lateral offset of the brace 25 allows the deck 40 to engage the flange 22 b closest to the brace 25 (the lower flange 22 b in FIG. 13 ) when the side rails 22 are in the second (or inverted) orientation (see FIG. 3 ).
- the braces 25 are advantageously located entirely outside the vertical projection of the perimeter of the deck 40 so that the braces 25 do not interfere with placement of the deck 40 against the support surfaces of the side rail 22 when the side rail assembly is inverted. See FIG. 14 .
- the lateral offset of the brace 25 applies at least to the end of the brace mated to the side rail 22 , but that the end of the brace 25 mating to the guide channel 24 may or may not be laterally offset relative to the center of the guide channel, as is desired.
- a plurality of alignment pins 21 are optionally mounted to the side rail 22 so as to extend from one or optionally both support surfaces of the side rail 22 .
- the alignment pins 21 are intended to extend into/through corresponding holes in the deck 40 to facilitate maintaining alignment of the deck relative to the side rails 22 .
- FIG. 14 Also shown in FIG. 14 are alternative embodiments of locking pins 42 , which extend through the stiffening element of the side rail 22 , and are described more fully in PCT/US2022/030542, filed 23 May 2022 (the disclosure of which is incorporated herein by reference in its entirety). Further shown in FIG.
- the releasable locking mechanism 30 is advantageously vertically spaced from the side rail 22 so that there is a gap between the releasable locking mechanism 30 and the side rail 22 .
- the concepts illustrated in FIGS. 12 - 14 such as the laterally offset braces 25 , the alignment pins 21 , and the spacing of the releasable locking mechanism 30 from the side rail 22 , may optionally be present in the other embodiments of the scaffold 10 described herein, alone or in any combination.
- a lightweight, multi-function scaffold with reversible side rails is more versatile than conventional multifunction scaffolds and enables use of the scaffold over a greater range of height requirements while increasing stability.
- the adjustable height platform When the side rails are in the first orientation, the adjustable height platform is vertically movable between a first threshold and a maximum height.
- the adjustable height platform When the side rails are in the second orientation, the adjustable height platform is vertically movable between a second threshold and a minimum height.
- the ranges of movement in the first and second orientations may overlap.
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Abstract
Description
- This application is a continuation-in-part of PCT/US2021/061010, filed 29 Nov. 2021; and claims benefit of U.S. Provisional Application No. 63/119,436, filed 30 Nov. 2020, and U.S. Provisional Application No. 63/168,780, filed 31 Mar. 2021, and U.S. Provisional Application No. 63/171,312, filed 6 Apr. 2021; the disclosures of each of which are incorporated herein by reference in their entirety.
- The present disclosure relates generally to lightweight scaffolding and, more particularly, to a lightweight, multi-function scaffold with a reversible platform.
- Lightweight scaffolds made from metal tubing are commercially available for use when working close to the ground. One such scaffold comprises an adjustable height platform supported between two ladder frames. The platform includes two side rails with guide channels at each end that slide up and down along the vertical supports of the ladder frames. Casters insert into the lower ends of the vertical supports so that the scaffold can roll on the floor or other support surface. Also, the scaffolds are configured to be stacked vertically. Stability of the scaffold is provided by a braces that connect the guide channels to the platform.
- The design of lightweight scaffold involves a trade-off between the height adjustment range and stability. Lightweight scaffolds tend to be less stable than typical heavy-duty scaffolding. Stability can be increased in two ways: by reducing the amount of play between the vertical supports of the ladder frame and the guide channel makes, and by reducing the flex of the ladder frame at the upper end of the adjustment range. Increasing the length of the guide channels at the ends of the side rails achieves both of these stability enhancements.
- While increasing the guide channel length provides greater stability, it comes at the cost of significantly less adjustment range. The movement of the guide channels that slide along the legs is limited by interference with other components of the scaffolding. For example, when the platform is lowered, the guide channels may come into contact with other components. Because the guide channels extend down from the platform, the interference with other components establishes a lower limit on the platform height. Reducing the length of the guide channel would enable the platform to be lowered closer to the ground but would make the scaffolding less stable. Therefore, the length of the guide channels for lightweight scaffolding currently on the market compromises the adjustment range in order to improve stability.
- The present disclosure provides a lightweight scaffold designed to provide a greater range of height adjustment while at the same time greatly increasing stability. Greater stability is achieved in by increasing the length of the guide channels. Greater range of height adjustment is achieved by making the platform reversible so that it can be mounted between the ladder frames in either a first orientation or in a second orientation. Making the platform reversible increases the range of height adjustment in two ways. First, orienting the platform so that the guide channels extend in an upward direction allows the platform to be lowered closer to the ground than conventional designs. When the platform is oriented with the guide channels extending downwardly, the increased length enables the platform to be raised above an upper end of the ladder frame while maintaining stability. The stability can be enhanced by properly clamping the guide channel to the vertical supports of the ladder frame to remove play between the guide channels and the vertical supports.
- According to another aspect of the disclosure, further increase in the adjustment range is achieved by providing openings in the guide channels that align with the openings in the vertical supports of the ladder frame used for connecting a caster or other ground engaging member. In a conventional scaffold, the caster or other ground engaging member includes a stem that inserts into the lower end of the vertical supports and is secured by a span pin that passes through aligned openings in the vertical support and in the stem of the caster. The guide channel cannot extend below the span pin so the span pin limits the range of movement. In exemplary embodiments disclosed herein, an opening is provided in the guide channel that aligns with the openings in the vertical support and caster stem when the platform is lowered to a predetermined height. The addition of the opening allows the platform to be lowered below the span pin to further increase the adjustment range.
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FIG. 1 is a perspective view of a scaffold including two ladder frames and an adjustable height platform according to one exemplary embodiment. -
FIG. 2A is a side view of the scaffold with the platform adjusted to a top of the ladder frame. In some embodiments, this is the maximum height. -
FIG. 2B is a side view of the scaffold with the platform adjusted to a height above the top end of the ladder frame. -
FIG. 3 is a side view of the scaffold with the platform adjusted to minimum height. -
FIG. 4A is a partial perspective view of a side rail and guide channel for the adjustable height platform. -
FIG. 4B is partial perspective view of a side rail and guide channel for the adjustable height platform with the platform extending above the height of the ladder frame. -
FIGS. 5A and 5B are cross section views of exemplary side rails for the adjustable height platform. -
FIG. 6 is a partial top plan view of the platform showing a locking mechanism to secure the deck to the side rails of the adjustable height platform. -
FIG. 7 illustrates compact stacking of two ladder frames for shipment or storage. -
FIG. 8 is an exploded perspective view illustrating a first method of mounting a caster to the scaffold. -
FIG. 8A is a perspective view illustrating an alternate method for mounting the caster to the scaffold -
FIG. 9 is an exploded perspective view of a stacking pin for the scaffold. -
FIG. 10 schematically illustrates the adjustment range of the adjustable height platform. -
FIG. 11 illustrates a method of adjusting the height of the platform for the scaffold. -
FIG. 12 shows a perspective view of an alternative embodiment of a side rail assembly with a curved brace. -
FIG. 13 shows a cross-sectional view of the side rail ofFIG. 12 taken along XIII-XIII. -
FIG. 14 shows a partial perspective view of a scaffold using the side rail assembly ofFIG. 12 , with the side rail in the second orientation for adjustment of the platform to a minimum height. - Referring now to the drawings,
FIG. 1 illustrates amulti-purpose scaffold 10 according to an exemplary embodiment. Themulti-purpose scaffold 10 comprises twoladder frames 12 and anadjustable height platform 20 supported between the twoladder frames 12. As described in greater detail below, theside rails 22 of theadjustable height platform 20 can be mounted between theladder frames 12 in two different orientations depending on a height requirement for a task. The first orientation enables theplatform 20 to be adjusted to its maximum height. The second orientation enables theplatform 20 to be adjusted to its minimum height. In one embodiment, the adjustment range is between a maximum height of about 78.5 inches and a minimum height of about 10 inches providing an adjustment range of 68.5 inches. For comparison, the maximum height for conventional lightweight scaffolds of this type is about 71 inches and the minimum height for conventional lightweight scaffolds is about 27 inches providing an adjustment range of only 44 inches. In this example, the design enhancement yield a 55% increase in the adjustment range. The first orientation is for relatively greater heights, i.e., farther from the ground, and the second orientation is for relatively lower heights, i.e., closer to the ground. - Each
ladder frame 12 comprises twovertical supports 14 connected by two ormore cross members 16. The vertical supports 14 andcross members 16 are preferably made of a metal tubing or other tubular material. Thecross members 16 are preferably welded at each end to respective ones of thevertical supports 14 so that eachladder frame 12 is a unitary structure. - In one embodiment, the
vertical supports 14 have a square or rectangular cross-section and thecross members 16 have a circular cross-section. The outside diameter of thecross members 16 is less than the width of thevertical support 14. Thecross members 16 can be offset from the center of thevertical supports 14 and the ends of thecross members 16 can be crimped or compressed to facilitate more compact stacking as shown inFIG. 7 . - A series of aligned
openings 18 extend through thevertical supports 14 perpendicular to the plane of theladder frame 12 and are spaced 2 inches apart. As will be hereinafter described in more detail, theopenings 18 are engaged by areleasable locking mechanism 30 on theplatform 20 to secure theplatform 20 at a desired height between the ladder frames 12. Additionally,openings 18 a extend transversely through the lower end of eachvertical support 14. These opening 18 a are used to securecasters 50 to thevertical supports 14 when theside rail 22 is in the lowermost position as will be hereinafter described. - Referring to
FIG. 4A , theplatform 20 comprises two side rail assemblies that extend between the ladder frames 12 and adeck 40 that is supported by the side rail assemblies. Each side rail assembly comprises aside rail 22 and twoguide channels 24 at opposing ends of theside rail 22. The side rails 22 are configured to provide a support surface for thedeck 40 in both a first orientation and a second orientation. Two variations of theside rail 22 are shown inFIGS. 5A and 5B respectively. In both cases, the cross section of theside rail 22 is symmetrical about a horizontal plane H. In the embodiment shown inFIG. 5A , theside rail 22 comprises a generally C-shaped channel with acentral web 22 a twoparallel flanges 22 b. Stiffeningflanges 22 c extend outwardly from the outer ends of theparallel flanges 22 b. In this embodiment, oneparallel flange 22 b provides a support surface for thedeck 40 in a first orientation and the other provides a support surface for thedeck 40 in the second orientation. In effect, the stiffeningflanges 22 c and theparallel flanges 22 b form upper and lower bounded notches that include the support surfaces for the first and second orientations, respectively, and these bounded notches are disposed inward relative to the stiffening elements in the form offlanges 22 c. - In the embodiments shown in
FIG. 5B , theside rail 22 comprises a generally C-shaped channel with acentral web 22 a and twoparallel flanges 22 b as previously described with twoadditional channels 22 d attached to the outer ends of theparallel flanges 22 b. Like the previous embodiment, theparallel flanges 22 b function as support surfaces for thedeck 40 in the first and second orientations respectively. Thus, like described above, thechannels 22 d and theparallel flanges 22 b form upper and lower bounded notches that include the support surfaces for the first and second orientations, respectively, and these bounded notches are disposed inward relative to the stiffening elements in the form of thechannels 22 d. Theadditional channels 22 d provide greater strength and rigidity compared to the design inFIG. 5A . - The side rails 22 are equipped with
internal latches 42 to hold thedeck 40 down once thedeck 40 is put in place. Thelatches 42 are mounted to theparallel flanges 22 b of theside rail 22 and are configured to project up throughslots 40 a (FIG. 6 ) in thedeck 40. Thelatches 42 include acatch element 42 a connected to a spring-biasedlatch pin 42 b that pulls thecatch element 42 a down into contact with the top surface of thedeck 40. Thelatch pin 42 b with the attachedcatch element 42 a is rotatable. To secure thedeck 40 in place, thelatch pin 42 b and attachedcatch element 42 a are rotated so that thecatch element 42 a can pass through theslot 40 a in thedeck 40 while thedeck 40 is being lowered into place. Once thedeck 40 is in place,latch pin 42 b is pushed upward and then rotated so that thecatch element 42 engages the upper surface of thedeck 40 as shown inFIG. 6 . Thelatch pin 42 b is biased by aspring 42 c so that when thelatch pin 42 b is released, thecatch element 42 b presses thedeck 40 down against the support surface, thus preventing thedeck 40 from lifting up off theside rail 22. - Referring back to
FIG. 4A , the ends of eachside rail 22 connect directly or indirectly to a C-shapedguide channel 24 sized to fit around thevertical supports 14 of the ladder frames 12. In one embodiment, asquare sleeve 23 is interposed between each end of theside rail 22 and theguide channel 24 for mounting a safety rail to the platform. Thesleeve 23 is configured to receive posts P of the safety rail (not shown), which can be secured to thesleeve 23 by locking pins (not shown). In one embodiment, theside rail 22,sleeves 23, and guidechannels 24 for each side rail assembly are welded together to form a unitary structure. - The
guide channels 24 comprises a C-shaped channel and are configured to slide along thevertical supports 14 of the ladder frames 12 at each end of thescaffold 10 to adjust the height of theplatform 20. Twoopenings 26 are formed in the inner flanges of eachguide channel 24 for locking theguide channel 24 at a selected height as hereinafter described. Theopenings 26 are spaced to align with theopenings 18 in thevertical supports 14 of theladder frame 12 at preselected heights. Theopenings 26 in theguide channels 24 are engaged by a releasable locking mechanism 30 (described below) on theplatform 20 to secure theplatform 20 at a desired height between the ladder frames 12. Athird opening 28 is formed near a lower end of theguide channel 24 and aligns with anopening 18 in thevertical support 14. A lockingpin 29 passes through aligned 28 and 18 in theopening guide channel 24 andvertical support 14 respectively. The lockingpin 29 serves as a failsafe and provides additional safety in case thelocking mechanism 30 inadvertently disengages.Diagonal braces 25 connect a lower end of eachguide channel 24 to theside rail 22 to increase the strength and rigidity of the assembledscaffold 10. The increased stability enhances worker’s confidence when standing on the scaffold. - Each
guide channel 24 includes areleasable locking mechanism 30 for locking theplatform 20 at a desired height. In one embodiment, thereleasable locking mechanism 30 comprises aU-shaped locking pin 32 that engages with the aligned 26 and 18 in theopenings guide channel 24 andvertical supports 14 respectively to lock theside rail 22 at a desired height. Each lockingpin 32 includes a pair of spaced apartlegs 32 a connected by across member 32 b. Abracket 34 supports the lockingpin 32. Thebracket 34 includes a pair ofopenings 36 through which thelegs 32 a of the lockingpin 32 extend.Springs 38 surrounding eachleg 32 a of the lockingpin 32 and bias the lockingpin 32 to a locked position. Thesprings 38 are compressed when the lockingpin 32 is pulled back to disengage the lockingpin 32 and push thelocking pin 32 back to an engaged position when the lockingpin 32 is released. - The
guide channel 24 as herein described is increased in length in comparison to prior art designs. The increased length enables the platform to be adjusted to a height above the top end of the ladder frames as shown inFIG. 4B . By increasing the length of theguide channels 24 from about 18 inches to about 23 inches, the maximum height for the platform can be increased from about 71 inches to about 78.5 inches. - In some embodiments, the
scaffold 10 includescasters 50 disposed at the lower end of eachvertical support 14 as shown inFIG. 8 . Eachcaster 50 includes astem 52 that extends into the lower end of avertical support 14. Thestem 52 is sufficiently long to overlap at least twoopenings 18 in the lower end of thevertical support 14. Thestem 52 of thecaster 50 includes anopening 54 that is located to align with anopening 18 in thevertical support 14 when thestem 52 of thecaster 50 is inserted into thevertical support 14. A lockingpin 56 passes through aligned 54 and 18 in theopenings caster 50 andvertical support 14 respectively to secure thecaster 50 to thevertical support 14. - In one embodiment, the
stem 52 further includes asecond opening 58 oriented 90 degrees relative to thefirst opening 54. Thesecond opening 58 is for use when theplatform 20 is adjusted to the minimum height as shown inFIG. 3 . In this case, the obstruction of theguide rail 20 prevents insertion of the lockingpin 56 through the aligned 54 and 18 in theopenings caster 50 andvertical support 14. In this case, thesecond opening 58 aligns with opening 18 a in the vertical support and anopening 27 in theguide channel 24 of theside rail 20 so that the lockingpin 56 can be inserted through the aligned 58, 18 a and 27 to secure theopenings caster 50 to thevertical support 14. -
FIG. 8A show an alternate embodiment, where thecaster 50 includes ssingle opening 54 as previously described. In this embodiment, the opening 18 a in thevertical support 14 is vertically aligned with anopening 18. In this case, thecaster 50 can be turned 90 degrees so that theopening 54 aligns with opening 18 a in the vertical support and theopening 26 in theguide channel 24 of theside rail 20 when the side rail is in the lowermost position as shown inFIG. 3 . - In some embodiments, the
casters 50 can be replaced by footpads, level jacks or socket levelers (not shown) or other ground-engaging member. comprising a generally flat pad that contacts the ground or underlying surface and a stem that extends into that extends into the lower end of avertical support 14. - In a
conventional scaffold 10, theguide channel 24 cannot extend below thespan pin 56 securing thecaster 50 or other ground engaging member the lower end of the vertical supports 14. Thus, thespan pin 56 limits the range of movement at the lower end of the adjustment range. In exemplary embodiments disclosed herein, anopening 27 is provided at each end of theguide channel 24 that aligns with the 18 a and 58 in theopenings vertical support 14 and caster stem 52 respectively when theplatform 20 is lowered below thespan pin 56. The addition of theopenings 27 allows theplatform 20 to be lowered below thespan pin 56 to further increase the adjustment range. In a conventional scaffold, thespan pin 56 is 2.5 inches above the caster flange. Providing theadditional openings 27 in the guide channel allow the platform to be lowered by an additional 2.5 inches plus ½ the diameter of thespan pin 56. - In some embodiments, the ladder frames 12 include removable stacking
pins 60 at the upper ends of the vertical supports 14. As shown inFIG. 9 , the stackingpins 60 include a threadedend 60 a that screws into anopening 62 a in a mountingblock 62 at the upper end of the vertical supports 14. The ability to remove the stacking pins enables more compact packaging for shipments and storage. Additionally, the design enables the use of interchangeable stacking pins of different size and/or shape. - When assembled, the
scaffold 10 provides a free-standing, self-supporting structure. Outriggers 70 can be used with the scaffold to increase stability by providing a wider base. Conventional outriggers 70 for lightweight scaffolds are designed to extend out from the sides of the scaffold in a lateral direction, i.e., perpendicular to the longitudinal axis. This arrangement reduces the risk of tipping sideways but does not improve stability in the longitudinal dimension. - The multifunction scaffold as herein described provides a greater range of adjustment in the height of the
platform 20. To obtain maximum height, the side rails 22 of theplatform 20 are mounted between the ladder frames 12 in a first orientation as shown inFIGS. 2A-2B . To obtain the minimum height, the side rails 22 of theplatform 20 are inverted and mounted between the ladder frames 12 in a second orientation as shown inFIG. 3 . -
FIG. 10 is a schematic illustration showing the range of adjustment of theplatform 20 in the first and second orientations. For reference, the term first orientation is used as a label for the configuration shown inFIGS. 2A-2B and the term second orientation is used a label for the configuration shown inFIG. 3 . In the first orientation, the downward movement is limited by theguide channels 24, which extend downward in this configuration. The lower bound of the downward movement is referred to as the first threshold. In this orientation, theplatform 20 is adjustable to a height between the first threshold and a maximum height. In the second orientation, the guide channel extends upward and limit the upward movement of theplatform 20. The upper bound of the movement is referred to as the second threshold. In this orientation, theplatform 20 is adjustable to a height between the minimum height and the second threshold. -
FIG. 11 illustrates an exemplary method of configuring the scaffolding for use. Prior to assembly of thescaffold 10, user determines a height requirement for a particular task (block 110). Based on the height requirement, the user selects either the first orientation or the second orientation (block 120). If the height requirement is greater than the first threshold, the user can install theplatform 20 in the first orientation (block 130). If the height requirement is less than the second threshold, the user can install theplatform 20 in the second orientation (block 140). If the height requirement is greater than the first threshold and less than the second threshold, the user can install theplatform 20 in either the first orientation or the second orientation (block 150). -
FIG. 12 shows an alternative embodiment of a side rail assembly, with acurved brace 25. As can be seen inFIG. 13 , thebrace 25 is located outwardly laterally offset relative to theflanges 22 b forming the support surfaces for thedeck 40. Thus, for the embodiment ofFIG. 13 , thebrace 25 mates to theside rail 22 at the stiffening element, which is located laterally outward (to the left inFIG. 13 ) relative to the correspondingflange 22 b. This lateral offset of thebrace 25 allows thedeck 40 to engage theflange 22 b closest to the brace 25 (thelower flange 22 b inFIG. 13 ) when the side rails 22 are in the second (or inverted) orientation (seeFIG. 3 ). Thebraces 25 are advantageously located entirely outside the vertical projection of the perimeter of thedeck 40 so that thebraces 25 do not interfere with placement of thedeck 40 against the support surfaces of theside rail 22 when the side rail assembly is inverted. SeeFIG. 14 . Note that the lateral offset of thebrace 25 applies at least to the end of the brace mated to theside rail 22, but that the end of thebrace 25 mating to theguide channel 24 may or may not be laterally offset relative to the center of the guide channel, as is desired. - As can also be seen in
FIG. 13 , a plurality of alignment pins 21 are optionally mounted to theside rail 22 so as to extend from one or optionally both support surfaces of theside rail 22. The alignment pins 21 are intended to extend into/through corresponding holes in thedeck 40 to facilitate maintaining alignment of the deck relative to the side rails 22. Also shown inFIG. 14 are alternative embodiments of lockingpins 42, which extend through the stiffening element of theside rail 22, and are described more fully in PCT/US2022/030542, filed 23 May 2022 (the disclosure of which is incorporated herein by reference in its entirety). Further shown inFIG. 14 is that thereleasable locking mechanism 30 is advantageously vertically spaced from theside rail 22 so that there is a gap between thereleasable locking mechanism 30 and theside rail 22. The concepts illustrated inFIGS. 12-14 , such as the laterally offsetbraces 25, the alignment pins 21, and the spacing of thereleasable locking mechanism 30 from theside rail 22, may optionally be present in the other embodiments of thescaffold 10 described herein, alone or in any combination. - A lightweight, multi-function scaffold with reversible side rails is more versatile than conventional multifunction scaffolds and enables use of the scaffold over a greater range of height requirements while increasing stability. When the side rails are in the first orientation, the adjustable height platform is vertically movable between a first threshold and a maximum height. When the side rails are in the second orientation, the adjustable height platform is vertically movable between a second threshold and a minimum height. The ranges of movement in the first and second orientations may overlap.
Claims (19)
Priority Applications (1)
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|---|---|---|---|
| US18/097,349 US20230151620A1 (en) | 2020-11-30 | 2023-01-16 | Multi-Function Scaffold with Reversible Platform |
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| US202063119436P | 2020-11-30 | 2020-11-30 | |
| US202163168780P | 2021-03-31 | 2021-03-31 | |
| US202163171312P | 2021-04-06 | 2021-04-06 | |
| PCT/US2021/061010 WO2022115703A1 (en) | 2020-11-30 | 2021-11-29 | Multi-function scaffold with reversible platform |
| US18/097,349 US20230151620A1 (en) | 2020-11-30 | 2023-01-16 | Multi-Function Scaffold with Reversible Platform |
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| PCT/US2021/061010 Continuation-In-Part WO2022115703A1 (en) | 2020-11-30 | 2021-11-29 | Multi-function scaffold with reversible platform |
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| US18/097,349 Pending US20230151620A1 (en) | 2020-11-30 | 2023-01-16 | Multi-Function Scaffold with Reversible Platform |
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| US17/537,163 Pending US20220186507A1 (en) | 2020-11-30 | 2021-11-29 | Multi-Function Scaffold with Reversible Platform |
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|---|---|---|---|---|
| US20210062580A1 (en) * | 2019-08-30 | 2021-03-04 | Grady F. Smith | Stabilization of Multi-Purpose Scaffold |
| US20220186507A1 (en) * | 2020-11-30 | 2022-06-16 | Grady F. Smith | Multi-Function Scaffold with Reversible Platform |
| US12044022B2 (en) * | 2021-04-09 | 2024-07-23 | Grady F. Smith & Co., Inc. | Locking pin for multifunction scaffold |
| USD1065598S1 (en) * | 2022-06-23 | 2025-03-04 | Yangzhou Superman Sporting Equipment Co., Ltd. | Scaffold |
| USD1101200S1 (en) * | 2024-07-09 | 2025-11-04 | Zhejiang Dongrui Industrial and Trading Co., Ltd. | Scaffold |
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