Note: Descriptions are shown in the official language in which they were submitted.
CA 02330371 2001-O1-08
DOCKET NO: 8528-004-64
TITLE OF THE INVENTION
ROOF STEP SYSTEM
This application claims priority from U.S. Provisional Application Serial
No. 60/174,714 filed January 6, 2000. The entirety of that provisional
application
is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a step system for providing a toehold/slide guard
on inclined surfaces, such as a roof.
Discussion of the Background
Providing a safe and secure foothold for workers working on an inclined
surface, such as a roof, has been a concern in the construction industry for
years.
The most common method for providing a foothold on a roof today is by nailing
a
2 x 4 (as used herein, 2" x 4" refers to a 2 inch by 4 inch piece of lumber)
directly
to the roof. This method has several disadvantages First, nailing a 2 x 4 to
the
roof creates holes in existing roofing materials. Second, because there is no
protective material surrounding the 2 x 4, workers using the 2 x 4 as a
toehold/slide
guard will often dislodge granular material that is attached to roof shingles.
Third,
the lack of protective material around the roof step allows soil and other
debris
from workers' shoes to be deposited on the roof.
The above identified short comings associated with the use of a 2 x 4 for
toeholds/slide guards has led to the development of a number of alternative
systems. These alternative systems can generally be classified into one of two
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categories: 1) ladder-like roofing systems; and 2) platform systems. Ladder-
like
systems generally provide steps, similar to a ladder, that are intended to
allow a
worker to climb the roof. An example of a ladder-like system is the system
described in UK Patent No. 2,131,475. Systems such as these provide a number
of
steps, spaced approximately the same distance as steps in a ladder. One
drawback
to the system proposed in UK Patent No. 2,131,475 is that the system is
comprised
of a rigid board, which makes the system cumbersome for use on a roof. Another
example of a ladder-like system is disclosed in U.S. Patent No. 2,708,543.
This
system discloses a number of triangular steps attached to a flexible
rubber/foam
backing board. Although this system has the advantage of providing a flexible
backing, it still suffers from the relative disadvantage of being heavy and
cumbersome for use on a roof. More importantly, both of these ladder-like
systems
do not provide toeholds that are spaced sufficiently far enough apart to allow
a
worker to kneel between successive, or neighboring, toeholds. Thus, while such
ladder-like systems are useful for climbing a roof, such systems are not as
useful
for a roofer who needs to kneel while perched on a toehold to install roofing
shingles.
The second type of alternative roofing systems are platform based roofing
systems. An example of a platform based roofing system is disclosed in U.S.
Patent No. 4,946,123. This system consists of an angled bracket that holds a 2
x 4
at an angle with respect to the roof to provide toehold. This system suffers
from
many of the same drawbacks associated with using a single 2 x 4, including the
necessity of driving nails through the bracket to secure the bracket to the
roof.
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Several more complicated platform systems are also known in the art, including
those described in U.S. Patent No. 4,785,606; U.S. Patent No. 5,908,083; and
U.S.
Patent No. 5,624,006. These systems all provide good working surfaces, but are
complicated and clumsy for use on a roof. Variations on the platform based
S systems are mobile platforms that can be attached to a worker's feet such as
the
platform described in U.S. Patent No. 3,726,028 and UK Patent No. 2,131,475.
Systems such as these are also cumbersome to use on a roof. What is needed is
a
light weight, easy to use system that provides a toehold/slide guard for a
worker
that will allow the worker to kneel on the roof in order to perform tasks such
as
installing shingles.
SUMMARY OF THE INVENTION
The present invention overcomes to a great extent the deficiencies found in
the prior art discussed above by providing a step system comprising a number
of
spaced apart steps attached to a connecting material, wherein the steps are
spaced
sufficiently far apart to allow an adult to kneel between neighboring steps.
In
preferred embodiments, the connecting material is a light weight nylon and the
steps are formed from high strength, light weight plastic. Highly preferred
embodiments of the present invention employ a woven nylon material,
approximately 900-1,000 denier. This type of fabric has been found to exhibit
exceptional traction when used on asphalt shingles. The material is preferably
solid. Besides providing traction on the roof surface, the use of a "solid"
material
also protects the roof both from dirt and other debris and from worker's shoe
which
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tends to dislodge the granular material found on many asphalt shingles. The
connecting material may be provided with a number of grommets, suitable for
attaching the connecting material to the roof. In preferred embodiments of the
invention, the step system is of sufficient length such that it can be draped
over the
entire roof and secured in sections to the roof. In preferred embodiments, the
step
includes a handle, which may also be used to secure a life line to the step.
Preferably, the steps are separated by approximately 20 inches to
approximately 36
inches, which is generally sufficient to provide room for a worker to kneel
using
one step as a toeholdJslide guard. The step system may be any width, but as
preferably between approximately 18 inches to approximately 50 inches wide,
which is generally sufficiently wide to provide a toehold for both of a
worker's
feet.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant
features and advantages thereof will be readily obtained as the same becomes
better
understood by reference to the following detailed description when considered
in
connection the accompanying drawings, wherein:
Figure 1 is a perspective view of a roof step system according to the present
invention in use on a roof.
Figure 2 is a bottom view of the roof step system of Figure 1.
Figure 3 is a top view of the roof step system of Figure 1.
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Figure 4 is an enlarged top view of a portion of the roof step system of
Figure 1.
Figure 5 is a front view of the roof step system of Figure 1.
Figure 6 is a side view of the roof step system of Figure 1.
Figure 7 is a perspective view of a preferred embodiment of the roof step
according to the present invention.
Figure 7A is a perspective view of a functional application of the preferred
embodiment shown in Figure 7.
Figure 8 is a perspective view of another preferred embodiment of the roof
step according to the present invention.
Figure 9 is a perspective view of yet another preferred embodiment of the
roof step according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Refernng now to the drawings wherein like reference numerals designate
identical or corresponding parts throughout the several views, a perspective
view
of a roof step system 100 installed on the roof 10 of a building 20 is shown
in
Figure 1. A worker 30 is using the roof step system 100 to install shingles
12. As
shown in Figure 1, the roof step system 100 extends over the peak of the roof
10.
The roof step system may be attached to the other side of the roof before the
shingles are attached to that side, or may extend entirely over the other side
of the
roof and be attached at a place on the house, thereby avoiding the necessity
of
creating holes in the roof 10 sheathing. The spacing between successive steps
130
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on the roof system 100 allows the worker 30 to kneel between successive steps
130. The step system 100 also protects installed shingles 12 from being
scuffed
and dirtied by the worker's feet.
Figure 2 is a bottom view of the roof step system 100. Figure 2 illustrates
the connecting material 110. The connecting material 110 may be any material
that
is sufficiently strong to connect the step. In preferred embodiments, the
material
110 is solid, or closed (as used herein, a solid or closed material is a
material of a
sufficiently dense weave such that dirt and other debris is prevented from
passing
through the material 110). However, other types of material may also be used.
These other types of material may include open nets or meshes. It is also
possible
to use two thin strips of material spaced apart such that the strips of
material are
attached to opposite ends of a step 100. In a highly preferred embodiment of
the
present invention, the connecting material is made from a heavy gauge (900 to
1,000 denier) nylon pack cloth. This material has been found to exhibit
excellent
traction on commonly used asphalt roof shingles. As can be seen with reference
to
Figure 3, in an even more highly preferred embodiment of the invention, the
fabric
110 is reenforced by thin nylon strips 120, comprised of a 2 inch wide 6000
lb.
break strength nylon/seat belt webbing for added strength.
Still referring to Figure 3, a distance D separates the toehold 134 of one
step 130 from the start of a successive step 130. The distance D is chosen to
allow
a worker to kneel between successive steps 130. Preferably, the distance D is
between approximately 20 inches and approximately 36 inches.
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Referring now to Figure 4, it can be seen that the reenforcing strips 120
include grommets 140. The grommets are used to secure the step system 100 to a
nail, screw, or other object. Experience has shown that in many situations, a
single
grommet 140 on each side of the top of the step system 100 is sufficient to
secure
the step system 100. This is partially due to the excellent traction provided
by the
connecting material 110. However, a plurality of grommets 140 are provided to
allow multiple screws or nails to be used to secure the step system 100 to the
roof
for the sake of safety; especially when the step system 100 is used on an
uncovered
plywood roof. The multiple grommets 140 also allow the roof step system 100 to
be attached to a roof at a number of different points.
The step 130 is attached to the connecting material 110 by 6000 pounds of
nylon seat belt webbing 120. In the embodiment shown in Figure 4, two slots
138
per side are used to attach the step 130 to the connecting material 110
through the
reenforcing strip 120. Any number of fasteners other than nylon seat belt
webbing
138 could be used to secure the step 130 to the connecting material 110, but
nylon
seat belt webbing is preferred because the nylon webbing 120 has low profile
on
the opposite side of the material 110.
The step 130 includes a base 132 having a width W. The width W is
chosen to prevent the step 130 from tipping over when used as a toehold/slide
guard. In preferred embodiments, the width W is approximately 8 inches. The
width W of the connecting material is approximately 10 inches to approximately
inches wide. More preferably still, the step 134 may be comprised of an
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textured plastic, which has been shown to provide surprisingly good traction,
especially when sneakers are worn.
Referring now to Figure S, it can be seen that the step 130 includes a
toehold 134 of a height H. In preferred embodiments, the height H is equal to
approximately 4 inches. Greater heights H are also possible, but the use of
greater
heights would require an increase in the width W of the base 132 of the step
130.
Also shown in figure 5 is a handle 136, which is formed by removing portions
of
the toehold 134. The handle 136 provides a convenient surface for a worker to
grab. The handle 136 may also be used to provide a point at which a life line
could
be attached to the step system 100. Such a life line is intended to be a
short, e.g., 6
foot, life line. A short life line such as this prevents the step system 100
from
being exposed to excessive force in the event that a worker should lose his
footing.
Another advantage of a short life line is convenience of use.
The step 130 is preferably comprised of a high strength, light weight
plastic. Of course, other materials could also be used. For example, steps
comprised of aluminum, steel and/or vulcanized rubber are also possible. It
should
also be noted that it is possible to use the solid nylon seat belt webbing
6000
pounds connecting material 110 without steps 130. Used in this manner, the
connecting material 110 provides good traction while keeping the roof 10
clean.
As shown in Figures 5 and 6, the toehold 134 is solid other than the cutout
for the handle 136. One advantage to this arrangement is that the toehold 134
can
be used by a worker 30 as a tool rest as shown in Figure 1.
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Further as shown in Figure 7, in a preferred embodiment of the step 130,
the base 132 includes keyhole-shaped sleeves 142 that are designed to permit
passage of a nail, screw, or other fastener (not shown), in order to secure
the step
130 to the roof surface. The keyhole shape allows the step 130 to be removed
from
the fastener without having to remove and reinstall the fastener, or without
having
to remove the fastener and patch or repair the hole left by the removed
fastener.
Furthermore, the keyhole-shaped sleeve 142 permits step 130 when installed to
be
anchored in place by sliding the step 130 so that the fastener passes through
the
narrow portion of keyhole-shaped sleeve 142. In the example shown in Figure 7,
it is anticipated that 1.5 inch #10 Phillips head screws will be used, and
upon
removal of the step 130, the screws are simply countersunk into the roofing
material to maintain an impervious surface.
A further advantage to the preferred embodiment shown in Figure 7 is that
individual roof steps may be placed in irregular patterns as conditions
require. As
shown in Figure 7A, at the discretion of the user, connecting material 110 may
be
used between individually placed steps 130.
Figure 8 displays another preferred embodiment of the step 130, wherein
the step is especially suitable for use on vertical or steeply pitched planes.
In the
preferred embodiment shown in Figure 8, toehold 134 has non-skid surface 144
which permits the user to maintain stable footing while working on the
vertical or
steeply pitched plane. In the preferred embodiment shown in Figure 8, the non-
skid surface 144 is provided through a pattern of molded knurls, but the non-
skid
surface can also be provided through the use of applique, sand paint, or other
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techniques familiar to persons of ordinary skill in the art. Keyhole-shaped
sleeves
142 are preferably placed relatively close to toehold 134, to minimize the
stress on
the fasteners (not shown) that are used to attach step 130 to the roof or
steeply
pitched plane.
Turning to Figure 9, a further preferred embodiment of the step 130 is
shown, wherein the overall length of the step is increased, to permit
extensive
lateral movement by the user. The preferred embodiment shown includes multiple
keyhole-shaped sleeves 142, preferably placed at construction industry-
relevant
standardized intervals such as 16 inches and 24 inches. The embodiment
depicted
in Figure 9 further includes non-skid surface 144, and one edge of step 130
includes ruler demarcations 146 to indicate length from any point along step
130.
Multiple cutouts for handholds 136 permit one or more users conveniently and
safely to carry the preferred embodiment shown. As shown in Figure 9, it is
anticipated that the preferred embodiment of the step will be formed from 14
gauge
cold-rolled or cold-drawn steel, but any material of sufficient strength,
resilience,
resistance to corrosion and other desirable properties, which will be obvious
to
those of ordinary skill in the relevant art, may be used.
While the invention has been described in detail in connection with the
preferred embodiments known at this time, it should be readily understood that
the
invention is not limited to such disclosed embodiments. Rather, the invention
can
be modified to incorporate any number of variations, alterations,
substitutions or
equivalent arrangements not heretofore described but which are commensurate
with the spirit and scope of the invention. Accordingly, the invention is not
to be
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seen as limited by the foregoing description, but is only limited by the scope
of the
appended claims.
