Note: Descriptions are shown in the official language in which they were submitted.
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SCAFFOLD PLANK WITH END CONNECTOR AND METHOD OF MAKING
THE SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Patent Application
Serial No. 60/804,162 entitled SCAFFOLD PLANK WITH END CONNECTOR
AND METHOD OF MAKING THE SAME filed June 7, 2006.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
The present invention relates generally to scaffolding systems, and. more
particularly to a scaffold plank fabricated from a plastic material and
optionally
including end connectors which are configured to facilitate the firm
engagement of
the plank to a support frame structure.
As is well known in the building industry, scaffolding is virtually always
employed during various facets of exterior and/or interior building
construction or
refurbishment. Known scaffolding systems typically comprise steel support
frame
structures which are selectively engageable to each other in a stacked fashion
for
achieving a desired overall height. In addition to the support frame
structures, the
scaffolding system includes a multiplicity of elongate scaffold planks, each
of which
is horizontally extensible between a respective pair of the support frame
structures.
The prior art scaffold planks are most typically fabricated from wood. Indeed,
the use
of wood for the prior art scaffold planks has been a long standing tradition
in the
building industry
Though wood scaffold planks have been and continue to be generally suitable
for use in scaffolding systems, the use of wood for the scaffolding planks
gives rise to
certain shortcomings and deficiencies which detract from their overall
utility. More
particularly, scaffold planks fabricated from wood are susceptible to
splitting as well
as to dry rot. Additionally, when exteriorly used scaffolding systems are
subjected to
rain or thunder storms as often occurs, the resultant water soaking of the
wood
scaffold planks virtually doubles their weight as compared to when dry, thus
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substantially increasing the difficulty by which they are moved or otherwise
manipulated. Such water soaking of the wood scaffold planks also often results
in the
warping or twisting thereof. As will be recognized, due to their
susceptibility to
splitting, dry rot and warping/twisting, the prior art wood scaffold planks
have a
reasonably limited life span and require moderately frequent replacement.
Another drawback associated with the use of wood scaffold planks is the
common occurrence of scaffold setters experiencing splinters in their hands
when
working with the same. Indeed, occurrences of splinters can reach a level of
severity
resulting in the initiation of a workers compensation claim. Moreover, because
nails
are also often used in conjunction with wood scaffold planks, workers are more
susceptible to being injured by nails which are left there within.
A further problem associated with the use of wood scaffold planks is the
relatively high cost thereof attributable to diminishing supplies of lumber.
Indeed,
ongoing extensive worldwide deforestation and the related environmental and
ecological problems has, in addition to resulting in increases in the price of
lumber,
stimulated a movement to adopt lumber alternatives for purposes of
contributing to
the conservation and restoration of forests. These diminishing supplies of
lumber also
frequently give rise to delays in the delivery of lumber raw material to those
mills
which manufacture wood scaffold planks, thus resulting in periodic problems in
meeting the supply demands of the building industry. Though metal (e.g.,
aluminum)
scaffold planks have been developed in the prior art as an alternative to wood
planks,
such aluminum planks are extremely costly. Additionally, both the wood and
aluminum scaffold planks of currently known scaffolding systems lack
connectors
which are suited to allow the plank to be quickly and easily engaged to a
support
frame structure.
The present invention addresses these concerns by providing a scaffold plank
which is manufactured or fabricated from a plastic material and may optionally
be
provided with end connectors which are specifically sized and configured to
facilitate
the quick and easy interface of the plank to a scaffolding system support
frame
structure. As will be discussed below, the plastic scaffold plank of the
present
invention, though possessing the same level of structural integrity or
rigidity as the
prior art wood scaffold planks, does not have the same susceptibility to
splitting, dry
rot or warping/twisting. Additionally, the weight of the scaffold plank of the
present
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invention is the same whether wet or dry. The use of plastic for the scaffold
planks of
the present invention also eliminates occurrences of splinters, and
substantially
eliminates injuries potentially caused by nails left therein. Further, since
the scaffold
planks of the present invention may be fabricated from recycled/recyclable
plastic
material, they address the need of recycling used plastic into a useful
product, in
addition to satisfying the increasing desire in industry for lumber
alternatives. These,
and other features of the present invention will be described in more detail
below.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a scaffold plank
assembly for engagement to a scaffolding frame. The scaffold plank assembly
comprises an elongate, non-metal plank which defines opposed first and second
ends
and at least one interior cavity. Attached to respective ones of the opposed
ends of
the plank is a pair of end connectors. The end connectors each comprise a main
body
defining an arcuate engagement surface, and at least two arms which are
attached to
the main body. Each of the arms defines an arcuate engagement surface which is
substantially continuous with the body engagement surface. Attached to and
extending from the main body is at least one attachment finger which is
extensible
into the interior cavity of the plank. The body and arm engagement surfaces
are sized
and configured to be cooperatively engageable to the scaffolding frame.
In addition to the arcuate body engagement surface, the main body includes at
least two notches formed therein. The notches are sized and configured to
receive
respective ones of the arms of another end connector in a nesting fashion,
thus
allowing the end connectors of two adjacent scaffold planks to be
cooperatively
engaged to a common support bar of the scaffolding frame. Additionally,
disposed
within the attachment finger of the end connector is an aperture which may be
coaxially aligned with a pair of apertures disposed within the plank when the
attachment finger is fully advanced into the interior cavity thereof. These
coaxially
aligned apertures are adapted to receive an elongate pin which, when advanced
through the apertures and secured to the plank, maintains the end connector in
firm
engagement to the plank. The plank itself may further be provided with a non-
slip
texture which is formed directly within the outer, top surface of the top,
wall thereof.
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BRIEF DESCRIPTION OF THE DRAWINGS
These, as well as other features of the present invention, will become more
apparent upon reference to the drawings wherein:
Figure 1 is a top perspective view of a scaffold plank constructed in
accordance with a first embodiment of the present invention;
Figure 1A is a partial bottom perspective view of the scaffold plank shown in
Figure 1, illustrating the optional inclusion of a frame setting notch in the
underside
thereof;
Figure 2 is a partial top perspective, cut-away view of the scaffold plank
constructed in accordance with the first embodiment of the present invention,
illustrating its end cap as being exploded from the main body thereof;
Figure 2A is a front perspective view of the end cap of the scaffold plank of
the first embodiment of the present invention, the rear perspective view of
the end cap
being shown in Figure 2;
Figure 3 is a partial top perspective, cut-away view of a scaffold plank
constructed in accordance with a second embodiment of the present invention;
Figure 4 is a partial bottom perspective, cut-away view of the scaffold plank
shown in Figure 3, illustrating its bottom cover as being exploded from the
main body
thereof;
Figure 5 is an exploded view-of a scaffold plank constructed in accordance
with a third embodiment of the present invention, and the end connector used
in
conjunction therewith:
Figure 6 is a cross-sectional view of the end connector shown in Figure 5,
further illustrating the manner in which the end connector is engaged to a
segment of
a support frame structure;
Figure 7 is a top perspective view of a steel reinforcement plate of the end
connector shown in Figures 5 and 6;
Figures 8 and 9 are top perspective views illustrating the manner in which the
scaffold planks of the third embodiment including the end connectors shown in
Figures 5-7 are interfaced to a support frame structure;
Figure 10 is a perspective view illustrating the manner in which scaffold
planks of the third embodiment and the corresponding end connectors may be
interfaced to a support frame structure in side-by-side relation, and further
illustrating
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an optional corner connector which may be used in conjunction with the
scaffold
planks of the third embodiment;
Figure 11 is top perspective view of a scaffold plank constructed in
accordance with a fourth embodiment of the present invention having a pair of
end
5 connectors cooperatively engaged to respective ones of the opposed ends
thereof;
Figure 12 is bottom perspective view of the scaffold plank shown in Figure
11;
Figure 13 is top perspective view of the scaffold plank of the fourth
embodiment similar to Figure 11, but further illustrating one of the end
connectors as
partially exploded from one end of the scaffold plank;
Figure 14 is bottom perspective view of the scaffold plank shown in Figure
13;
Figure 15 is top plan view of the scaffold plank of the fourth embodiment
similar to Figure 13, but further illustrating one of the end connectors as
fully
exploded from one end of the scaffold plank;
Figure 16 is side perspective view of one end of the scaffold plank of the
fourth embodiment with the corresponding end connector removed therefrom; and
Figure 17 is top plan view of a connector pin which is used to secure each of
the end connectors to the scaffold plank of the fourth embodiment of the
present
invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein the showings are for purposes of
illustrating preferred embodiments of the present invention only, and not for
purposes
of limiting the same, Figure 1 perspectively illustrates a scaffold plank 10
constructed
in accordance with a first embodiment of the present invention. The scaffold
plank 10
has an elongate, generally rectangular configuration and includes a main body
12
which defines opposed ends. Attached to the respective ones of the opposed
ends of
the main body 12 is a pair of identically configured end caps 14, the precise
structural
attributes of which will be described in more detail below. In the first
embodiment,
the preferred height or thickness of the scaffold plank 10 is in the range of
from about
1.0 inch to about 2.50 inches, and is preferably about 1.50 inches. The
preferred
width of the scaffold plank 10 is in the range of from about 6.0 inches to
about 15.0
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inches, and is preferably about 9.50 inches. The overall length of the
scaffold plank
(including the main body 12 and end caps 14) is variable. In this respect, it
is
contemplated that the scaffold plank 10 may be provided to have an overall
length of
either 6 feet, 9 feet, 12 feet, or 16 feet. However, those of ordinary skill
in the art will
5 recognize that the scaffold plank 10 of the present invention may be
fabricated to have
length, width, and/or height dimensions differing from those described above.
As seen in Figures 1 and 1A, the scaffold plank 10 may be provided with two
pairs of pre-formed nail holes 16, with each pair of the nail holes 16 being
disposed
within the body 12 in relative close proximity to a respective one of the end
caps 14.
10 In addition to the nail holes 16, the main body 12 of the scaffold plank
may be formed
to include a spaced pair of arcuately contoured, concave frame setting notches
18 in
the underside or bottom surface 20 thereof. As will be described in more
detail
below, the nail holes 16 and/or frame setting notches 1.8, if included, are
preferably
formed in the main body 12 via finishing operations conducted subsequent to
the
fabrication of the main body 12. The nail holes 16 and/or frame setting
notches 18
are used to facilitate the engagement or interface of the scaffold plank 10 to
a
conventional steel frame support structure of a scaffolding system.
Referring now to Figures 2 and 2A, the main body 12 of the scaffold plank 10
itself comprises a top wall 22 which defines a top surface 24, a bottom wall
26 which
defines the bottom surface 20, and an opposed pair of longitudinally extending
sidewalls 28 which are integrally connected to the top and bottom walls 22,
26.
Integrally connected to and extending perpendicularly between the top and
bottom
walls 22, 26, and in particular the inner surfaces thereof, are five (5)
reinforcement
webs 30. The reinforcement webs 30 extend in generally parallel relation to
each
other, thus defining six (6) compartments of cavities which extend
longitudinally
within the interior of the main body 12. In the scaffold plank 10, the
preferred
thickness of the top, bottom and sidewalls 22, 26, 28 and reinforcement webs
30 is
approximately 0.1875 inches.
As further seen in Figure 2, formed on the inner surface of the top wall 22
and
extending longitudinally therealong in spaced, generally parallel relation to
each other
are seven (7) ribs 32. Similarly, forraed on and extending longitudinally
along the
inner surface of the bottom wall 26 in spaced, generally parallel relation to
each other
are seven (7) ribs 34 which are disposed in opposed, aligned relation to
respective
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ones of the ribs 32. The ribs 32, 34 extend generally perpendicularly from the
inner
surfaces of the top and bottom walls 22, 26, respectively. In the scaffold
plank 10, the
top, bottom and sidewalls 22, 26, 28 and ribs 32, 34 extending within the
outermost
pair of cavities collectively form a pair of slots which are each adapted to
accommodate an elongate, rectangularly configured reinforcement bar 36. The
centermost pair of ribs 32, 34, top and bottom walls 22, 26, and centermost
reinforcement web 30 also collectively define a slot which is adapted to
accommodate
a third reinforcement bar 36. The four remaining ribs 32 and four remaining
ribs 34
collectively define two more slots which extend within respective ones of
those
cavities disposed adjacent the outermost pair and are adapted to accommodate
two
additional reinforcement bars 36. In the scaffold plank 10, the reinforcement
bars 36
are each preferably fabricated from steel having a thickness of approximately
0.1875
inches.
In the scaffold plank 10 shown in Figure 2, three (3) reinforcement bars 36
are
depicted as being disposed within respective ones of the five (5) slots
extending
within the interior of the main body 12. Those of ordinary skill in the art
will
recognize that no reinforcement bars 36 need to be provided within the main
body 12,
and that less than three or up to five reinforcement bars 36 may be included
therein.
The number of reinforcement bars 36, if any, included in the interior of the
main body
12 of the scaffold plank 10 is dependent upon the level of structural
integrity or
rigidity desired in relation thereto. In the scaffold plank 10, each of the
reinforcement
bars 36 is preferably sized such that when disposed within the interior of the
main
body 12 in the above-described manner, the opposed ends thereof do not
protrude
beyond respective ones of the opposed ends of the main body 12.
As indicated above, in addition to the main body 12, the scaffold plank 10
includes the end caps 14 which are attached to respective ones of the opposed
ends of
the main body 12. As seen in Figures 2 and 2A, each of the end caps 14 has a
generally rectangular configuration, and includes an outer surface 38 which
defines a
pair of beveled or concave corner regions adjacent respective ones of the
lateral sides
thereof. In addition to the outer surface 38, each end cap 14 has an inner
surface 40
which includes an elongate channel 42 formed therein. The channel 42 is fonned
within each end cap 14 for purposes of reducing the overall weight thereof. As
seen
in Figure 2, the channel 42 terminates inwardly of the lateral sides of the
end cap 14.
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Formed on the inner surface 40 of each end cap 14 are a total of eight (8)
rectangularly configured attachment tabs 44. The attachment tabs 44 are
arranged in
two sets of four, with the attachment tabs 44 of each set being disposed in
spaced
relation to each other along a respective one of the longitudinal sides of the
channel
42. Additionally, the attachment tabs 44 of one set are disposed in opposed,
linear
alignment with respective ones of the attachment tabs 44 of the other set_
Importantly, the attachment tabs 44 are oriented so as to be advanceable into
respective ones of the cavities defined within the main body 12 and not
interfere with
any of the reinforcement webs 30 thereof. In this respect, the attachment tabs
44 are
sized and configured such that when each opposed pair thereof is received into
a
respective one of the cavities of the main body 12, those edges of the
attachment tabs
44 disposed furthest from the channel 42 are in abutting contact with the
inner
surfaces of respective ones of the top and bottom walls 22, 26 of the main
body 12.
Those of ordinary skill in the art will recognize that different numbers of
attachment
tabs 44 arranged in alternative patterns are contemplated in relation to the
end caps
14. In the scaffold plank 10, each of the end caps 14 may be sonically welded
to the
main body 12, or may alternatively be attached to the main body 12 through the
use of
fasteners such as pins, snap fit, or an adhesive. However, those of ordinary
skill in the
art will recognize that other methods may be employed to facilitate the
attachment of
the end caps 14 to the main body 12. As is seen in Figure 1, the end caps 14
are sized
relative to the main body 12 such that when attached thereto, the longitudinal
sides of
the end caps 14 are substantially flush with the bottom surface 20 of the
bottom wall
26 and top surface 24 of the top wall 22, with the lateral sides of the end
caps 14
being substantially flush with respective ones of the outer surfaces of the
sidewalls 28.
Both the main body 12 and end caps 14 of the scaffold plank 10 are preferably
fabricated from a plastic material. A preferred plastic material is a ten
percent to fifty
percent glass-filled polypropylene/nylon blend. Such plastic material may
alternatively comprise either virgin or recycled plastic. It is contemplated
that the
plastic or nylon material may be filled with either glass or another suitable
reinforcement material to increase the structural integrity/rigidity thereof.
Those of
ordinary skill in the art will further recognize that the main body 12 and end
caps 14
need not necessarily be fabricated from identical materials. In this respect,
each of the
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end caps 14 could be fabricated from a metallic material such as aluminum. As
indicated above, each of the reinforcement bars 36 is preferably fabricated
from steel.
Additionally, the main body 12 of the scaffold plank 10 is preferably
fabricated via an extrusion process. If one or more reinforcement bars 36 is
to be
included within the interior of the main body 12, it is preferred that the
plastic
material used to form the main body 12 will be extruded about the
reinforcement
bar(s) 36. However, those of ordinary skill in the art will recognize that the
reinforcement bars 36 may be inserted into the interior of the main body 12
via a
separate procedure which is conducted subsequent to the formation of the main
body
12 via the extrusion process. The end caps 14 are preferably fabricated
through the
use of an injection molding or vacuum forming process and, as indicated above,
secured to respective ones of the opposed ends of the main body 12 subsequent
to the
fabrication of the same.
Subsequent to the fabrication of the main body 12 via the extrusion process,
it
-
is contemplated that the nail holes 16 may be formed,therein via a follow-up
drilling
operation. Additionally, the frame setting notches 18 may be formed in the
bottom
surface 20 via a follow-up grinding or machining operation. Moreover, the top
surface 24 of the top wall 22 may be subjected to a grinding or machining
operation
for purposes of applying a texture or roughened feature thereto. Though not
shown, it
is further contemplated that the cavities defined by the main body 12 may be
filled
with structural foam or some equivalent thereto prior to the attachment of the
end caps
14 to the main body 12 for purposes of increasing the structural strength or
rigidity of
the completed scaffold plank 10.
Referring now to Figures 3 and 4, there is depicted a scaffold plank 100
constructed in accordance with a second embodiment of the present invention.
The
scaffold plank 100 also has an elongate, generally rectangular configuration
and
includes a main body having a top wall 104 which defines a top surface 106, an
opposed pair of longitudinally extending sidewalls 108 which are integrally
connected
to the top wall 104, and an opposed pair of end walls 110 which are integrally
connected to the top and sidewalls 104, 108 and define respective ones of the
opposed
ends of the scaffold plank 100. Though the scaffold plank 100 of the second
embodiment preferably does not include the previously described end caps 14
since
the opposed ends thereof are defined by the end walls 100 of the main body
102,
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those of ordinary skill in the art will recognize that such end caps 14 may be
employed as an alternative to the integrally formed end walls 100. Similar to
the
configuration of the outer surfaces 38 of the end caps 14, the end walls 110
of the
main body 102 may be formed to include beveled corner regions adjacent
respective
5 ones of the sidewalls 108.
As is seen in Figures 3 and 4, the main body 102 of the scaffold plank 100 is
formed to include four (4) channel members 112 which are integrally connected
to the
inner surface of the top wall 104 and extend longitudinally therealong in
spaced,
generally parallel relation to each other. The outermost pair of channel
members 112
10 each has a generally L-shaped configuration and, in addition to being
integrally
connected to the inner surface of the top wall 104, are integrally connected
to the
inner surfaces of respective ones of the sidewalls 108. The central two
channel
members 112 each have a generally U-shaped configuration and are integrally
connected to only the inner surface of the top wall 104. In the scaffold plank
100, the
outermost pair of channel members 112 and inner surfaces of the top and
sidewalls
104, 108 collectively define a pair of slots, with another pair of slots being
collectively defined by the central two channel members 112 and inner surface
of the
top wall 104. Each of these four (4) slots has a generally rectangular
configuration
and extends substantially along the length of the main body 102. Additionally,
each
of these slots is sized and configured to accommodate a reinforcement bar 114
which
is identically configured to the previously described reinforcement bar 36 and
preferably fabricated from steel.
In addition to the channel members 112, integrally connected to and extending
perpendicularly from the inner surface of the top wall 104 are three (3)
longitudinally
extending primary reinforcement webs 116. In the scaffold plank 100, each of
the
primary reinforcement webs 116 is disposed equidistantly between an adjacent
pair of
channel members 112 and extends in generally parallel relation thereto.
Integrally
connected to and extending angularly between each of the primary reinforcement
webs 116 and the channel members 112 of the corresponding pair are a plurality
of
secondary reinforcement webs 118 which are also integrally connected to the
inner
surface of the top wall 104 and extend generally perpendicularly relative
thereto. As
is best seen in Figure 4, the channel members 112 and primary and secondary
reinforcement webs 116, 118 are each sized and configured such that the distal
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surfaces thereof (i.e., those surfaces disposed furthest from the inner
surface of the top
wall 104) and are oriented inwardly from the distal edges of the sidewalls 108
and end
walls 110 (or end caps 14) of the main body 102. In this respect, the distal
edges of
the side and end walls 108, 110 of the main body 102 protrude slightly
outwardly
from the distal surfaces of the channel members 112 and primary and secondary
reinforcement webs 116, 118 for reasons which will be described in more detail
below.
In addition to the main body 102, the scaffold plank 100 of the second
embodiment may comprise a cover member 120 which also has an elongate,
generally
rectangular configuration and define opposed, generally planar surfaces. In
the
scaffold plank 100, the cover member 120 is attached to the main body 102 such
that
the inner surface of the cover member 120 lies in abutting contact with the
distal
surfaces of the channel members 112 and primary and secondary reinforcements
webs
116, 118. In this respect, the length and width dimensions of the cover member
120
are slightly smaller than those of the main body 102 such that when the inner
surface
of the cover member 120 is placed in abutting contact with the channel members
112
and primary and secondary reinforcement webs 116, 118 in the aforementioned
manner, the outer surface of the cover member 120 is substantially flush or
continuous with distal edges of the side and end walls 108, 110 of the main
body 102.
The attachment of the cover member 120 to the main body 102 is preferably
facilitated through the use of sonic welding, pins, or an adhesive. However,
those of
ordinary skill in the art will recognize that other methods may be employed to
facilitate the attachment of the cover member 120 to the main body 102. Since
the
cover member 120, when attached to the main body 102, does not protrude beyond
the side and end walls 108, 110 of the main body 102, the overall length,
width and
height dimensions of the scaffold plank 100 are governed by the main body 102
thereof. Though not shown, it is contemplated that a sealing strip will be
compressed
between the cover member 120 and the main body 102 when the cover member 120
is
attached to the main body 102.
In the second embodiment, the preferred height or thickness of the main body
102, and hence the scaffold plank 100, is in the range of from about 1.0 inch
to about
2.50 inches, and preferably about 1.50 inches. The preferred width of the main
body
102 is in the range of from about 6.0 inches to about 15.0 inches, and is
preferably
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about 9.50 inches. The overall length of the main body 102 is variable, with
it being
contemplated that the same may be provided in lengths of either 6 feet, 9
feet, 12 feet,
or 16 feet.
Like the main body 12 and end caps 14 of the scaffold plank 10 of the first
embodiment, both the main body 102 and cover member 120 of the scaffold plank
100 of the second embodiment are preferably fabricated from a plastic
material. As is
the first embodiment, a preferred plastic material is a ten percent to fifty
percent
glass-filled polypropylene/nylon blend. An alternative plastic material may be
either
virgin or recycled plastic. It is contemplated that the plastic or nylon
material may be
filled with either glass or another suitable reinforcement material to
increase the
structural integrity/rigidity thereof. As indicated above, each of the
reinforcement
bars 114 is preferably fabricated from steel. However, the reinforcement bars
114 as
well as the above-described reinforcement bars 36 may each be fabricated from
a
material other than steel.
In the scaffold plank 100 shown in Figures 3 and 4, four (4) reinforcement
bars 114 are depicted as being disposed within respective ones of the four (4)
slots
extending within the interior of the main body 102. Those of ordinary skill in
the art
will recognize that no reinforcement bars 114 need be provided within the main
body
102, and that less than four (4) reinforcement bars 114 may be included
therein. The
number of reinforcement bars 114, if any, included in the interior of the main
body
102 of the scaffold plank 100 is dependent upon the level of structural
integrity or
rigidity desired in relation thereto. Additionally, though the main body 102
is shown
as including four (4) channel members 112 and three (3) primary reinforcement
webs
116, those of ordinary skill in the art will recognize that the main body102
may be
formed to include greater or fewer channel members 112 and/or primary
reinforcement webs 116.
As indicated above, no reinforcement bars 114 need to be provided within the
main body 102. In this respect, it is contemplated that as an alternative to
the
reinforcement bars 114 being included in the main body 102, the channel
members
112 may be formed to be of a solid cross-sectional configuration as opposed to
partially defining the above-described rectangularly configured slots. In this
respect,
based upon the particular plastic material used to form the main body 102, the
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formation of the same with the solid channel members 102 may be sufficient to
impart
the desired amount of structural integrity/rigidity to the scaffold plank 100.
In the second embodiment, the main body 102 of the scaffold plank 100 is
preferably fabricated via an injection molding process, as is the cover member
120
thereof. If one or more reinforcement bars 114 is to be included within the
interior of
the main body 102, such reinforcement bar(s) 114 will typically be pre-
positioned
within the mold, with the plastic material thereafter being injection molded
about the
same, thus resulting in the reinforcement bars 114 being molded in place.
Additionally, as seen in Figure 3, it is contemplated that the mold may be
formed to
provide the top surface 106 of the top wall 104 with non-skid characteristics
through
the formation of multiple, generally circular protuberances 122 thereon, with
such
protuberances 122 being arranged in generally parallel rows. As an alternative
to
being formed to include the protuberances 122, the top surface 106 of the top
wall 104
may be subjected to a follow-up grinding or machining operation subsequent to
the
molding of the main body 102 for purposes of applying a texture or roughened
feature
thereto. The outer surface of the cover member 120 may also be formed to
include a
texture or roughened feature. Though the main body 102 and the cover member
120
are preferably fabricated via an injection molding process, it is contemplated
that
either or both of the main body 102 and cover member 120 may be fabricated via
a
vacuum forming or extrusion process. Additionally, though not shown, it is
contemplated that the previously described nail holes 16 and/or frame setting
notches
18 may be formed within the scaffold plank 100 via processes/techniques
similar to
those previously described in relation to the scaffold plank 10 of the first
embodiment.
It is contemplated in the scaffold plank 100 of the second embodiment, the
cover member 120 may be formed as an integral portion of the main body 102 as
opposed to a separate component attached thereto. In this respect, the main
body 102
including the cover member 120 as an integral portion thereof may be formed or
fabricated as a totally symmetrical component or part. Both of the sides or
faces of
such symmetrical part could be provided with a texture or roughened feature,
with the
absence of any nail holes 16 and frame setting notches 18 allowing the same to
be
positioned upon scaffolding in any orientation. If formed to include the cover
member 120 as an integral portion thereof, it is contemplated that the main
body 102
will be molded in two identical halves defined by bisecting the side walls 108
along a
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common plane. These two symmetrical halves of the main body 102 (one of which
would include the integrally formed cover member 120) would be attached to
each
other via sonic welding or an adhesive to facilitate the formation of the
scaffold plank
100. Each of the symmetrical halves could be individually fabricated via
injection
molding, rotational molding, or a vacuum forming process.
Referring now to Figure 5, there is shown a scaffold plank 200 constructed in
accordance with a third embodiment to the present invention. The scaffold
plank 200
is preferably outfitted with a pair of end connectors 202 which are
cooperatively
engaged to respective ones of the opposed ends of the scaffold plank 200. The
structural and functional attributes of each end connector 202 (one of which
is shown
in Figure 5 as exploded from the scaffold plank 200) will be described in more
detail
below.
As seen in Figure 5, the scaffold plank 200 is preferably a unitary structure
which defines a generally planar, sheet-like top wall 204 and a generally
planar,
sheet-like bottom wall 206. The top and bottom walls 204, 206 extend in spaced
relation to each other along respective ones of a generally parallel pair of
planes.
Extending perpendicularly between corresponding pairs of the longitudinal
edges of
the top and bottom walls 204, 206 is a spaced, generally parallel pair of side
walls
208. Though the inner surfaces of the side walls 208 are generally planar, the
outer
surfaces thereof each include an integral upper rail 210 and an integral lower
rail 212
extending longitudinally therealong in spaced, generally parallel relation to
each
other. The upper rails 210 extend along respective ones of the opposed
longitudinal
sides of the top wa11204, and are each substantially flush with the outer
surface of the
top wall 204. Similarly, the lower rails 212 extend along respective ones of
the
opposed longitudinal sides of the bottom wall 206 and are each substantially
flush
with the outer surface of the bottom wall 206. As shown in Figure 5, each of
the
upper and lower rails 210, 212 is preferably hollow, though the same may
alternatively be formed to have solid cross-sectional configurations. Due to
the
inclusion of the upper and lower rails 210, 212 thereon, each side wall 208
defines an
elongate slot 214, the use of which will also be discussed in more detail
below.
The scaffold plank 200 further comprises a plurality of reinforcement walls
216 which extend perpendicularly between the inner surfaces of the top and
bottom
walls 204, 206. The reinforcement walls 216 extend longitudinally along the
length
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of the scaffold plank 200 in spaced, generally parallel relation to each
other. Though
the reinforcement walls 216 are equidistantly spaced relative to each other,
the
spacing between the outermost pair of reinforcement walls 216 and respective
ones of
the side walls 208 is reduced in comparison to the spacing between the
reinforcement
5 walls 216. As a result, an outer pair of cavities collectively defined by
the top and
bottom walls 204, 206, outermost pair of reinforcement walls 216, and side
walls 208
each have a width which is less than that of multiple inner cavities which are
each
collectively defined by the top and bottom walls 204, 206 and an adjacent pair
of the
reinforcement walls 216. As seen in Figure 5, the scaffold plank 200 is formed
to
10 include five reinforcement walls 216. As a result, the scaffold plank 200
includes
four inner cavities and two outer cavities which, as indicated above, are of
reduced
width as compared to the inner cavities. However, those of ordinary skill in
the art
will recognize that the number of reinforcement walls 216 included in the
scaffold
plank 200 as shown in Figure 5 is exemplary only, in that greater or fewer
15 reinforcement walls 216 may be formed to extend between the top and bottom
walls
204, 206. Also exemplary is the spacing between the reinforcement walls 216,
in that
it is contemplated that the reinforcement walls 216 may be equidistantly
spaced
relative to each other and to the side walls 208, thus causing all of the
cavities defined
by the scaffold plank 200 to be of equal size.
It is contemplated that the scaffold plank 200 of the third embodiment will be
fabricated in its entirety from a non-metal material via an extrusion or
injection
molding process. Exemplary materials for the scaffold plank 200 include
various
types of plastics (e.g., glass-filled polyethylene), fiber reinforced
composites, or
combinations thereof. In this regard, it is further contemplated that the
extrusion
process preferably used to facilitate the formation of the scaffold plank 200
may be
carried out in a manner wherein various portions of the scaffold plank 200 are
fabricated from a fiber reinforced plastic or composite, with other portions
simply
being fabricated from a non-reinforced plastic material. More particularly,
depending
on the level of structural integrity desired for the scaffold plank 200, one
or more of
the reinforcement walls 216 may be fabricated from a fiber reinforced
composite
material, with the remainder of the scaffold plank 200 being fabricated from a
plastic
material. As indicated above, the extrusion process preferably used to
facilitate the
fonnation 'of the scaffold plank 200 may be completed such that the scaffold
plank
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200 is a unitary structure, despite proscribed areas of the scaffold plank 200
being
fabricated from differing non-metallic materials. As a further variation, the
scaffold
plank 200 as shown in Figure 5 may be fabricated entirely from a non-
reinforced
plastic material, with reinforcing sheets of a fiber reinforced composite
material being
applied to the outer surface of the top wall 204 and/or the outer surface of
the bottom
wall 206 for purposes of increasing the structural integrity/rigidity of the
scaffold
plank 200. In the scaffold plank 200, the outer surface of the top wall 204
and the
outer surface of the bottom vvall 206 are preferably formed to have a
roughened or
textured feature to provide the scaffold plank 200 with non-slip
characteristics.
However, those of ordinary skill in the art will recognize that the non-skid,
roughened
texture may be included on only the outer surface of the top wall 204.
Referring now to Figures 5-7, as indicated above, the scaffold plank 200 of
the
third embodiment preferably includes a pair of end connectors 202
cooperatively
engaged to respective ones of each of the opposed ends thereof. Each end
connector
202 includes an engagement portion 218 having a main body 220 which defines an
arcuate, generally concave body surface 222. The body surface 222 spans
approximately ninety degrees. Formed within the main body 220 is a spaced pair
of
notches 224, each of which has a generally V-shaped configuration defining an
arcuate lower apex. In addition to the main body 220, the engagement portion
218 of
the end connector 202 includes a spaced, identically configured pair of arms
226
which are integrally connected to the main body 220. Each of the arms 226
defines
an arcuate, generally concave arm surface 228 which, like the body surface
222, also
spans approximately ninety degrees. The main body 220 and arms 226 are
oriented
relative to each other such that one of the notches 224 is disposed between
the arms
226, with the remaining notch 224 being disposed between one arm 226 and one
lateral end of the main body 220. Importantly, the main body 220 and arms 226
are
oriented relative to each other such that the arms surfaces 228 of the arms
226 are
continuous with the body surface 222 of the main body 220. Thus, the arms
surfaces
228 and portions of the body surface 222 collectively define engagement
surfaces
which span, in total, approximately 180 . Each arm 226 also has a generally V-
shaped configuration when viewed from a top perspective, with the side walls
of the
arm 26 oriented between the notches 224 being continuous with the side walls
of such
notches 224. One side wall of the remaining arm 226 is continuous with the
side wall
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of the notch 224 disposed between the arms 226_ As seen in Figure 5, due to
the
shape of the engagement portion 218 of the end connector 202, the depth of the
notch
224 located between the arms 226 appears to be greater than that of the
remaining
notch 224 due to the side wall of the notch 224 between the arms 226 being
continuous with one side wall of each of the arms 226.
In addition to the engagement portion 218, the end connector 202 includes a
plurality of elongate attachment fingers 230 which protrude perpendicularly
from the
side of the main body 220 opposite that including the body surface 222 formed
therein. The fingers 230 extend in spaced, generally parallel relation to each
other,
and are each preferably hollow. As is best seen in Figure 5, the fingers 230
are sized
and configured to be advanceable into respective ones of the cavities defined
by the
scaffold plank 200. In this regard, since the cavities of the scaffold plank
200 are of
differing widths as indicated above, the outermost pair of fingers 230 of the
end
connector 202 are of reduced width as compared to the remaining fingers 230.
In this
regard, the outermost pair of fingers 230 are sized and configured to be
advanceable
into respective ones of the outer pair of cavities defined by the scaffold
plank 200,
with the remaining fingers 230 being sized and configured to be advanceable
into
respective ones of the inner cavities defined by the scaffold plank. 200. The
advancement of the fingers 230 into respective ones of the cavities is limited
by the
abutment of a peripheral portion of the surface of the main body 220 from
which the
fingers 230 extend against corresponding lateral edges of the top and bottom
walls
204, 206 and side walls 208 of the scaffold plank. 200, in the manner shown in
Figure
6.
It is contemplated that the end connector 202 will be fabricated from a
plastic
material via an injection molding process, with the attachment fingers 230
being
integrally connected to the main body 220 of the engagement portion 218. As
seen in
Figures 6 and 7, it is further contemplated that the structural integrity of
each end
connector 202 may optionally be increased through the inclusion of a
reinforcement
plate 244 therein. The reinforcement 244 is preferably fabricated from a metal
material (e.g., steel), and has a shape which is complimentary to that of the
main body
220, arms 226, and fingers 230. More particularly, the reinforcement plate 244
includes a plurality of reinforcement fingers 246 which are sized and
configured to be
advanceable into the interiors of respective ones of the attachment fingers
230.
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Additionally, the reinforcement plate 244 includes a pair of arcuate
reinforcement
arms 248 which are extensible into the interiors of respective ones of the
arms 226.
Since the end connector 202 is preferably fabricated via an injection molding
process,
it is contemplated that the reinforcement plate 244 will initially be included
in the
mold cavity, with the plastic material used to form the remainder of the end
connector
202 being injected into the mold cavity in a manner effectively encapsulating
the
reinforcement plate 244 in the manner shown in Figure 6.
As indicated above, the cooperative engagement of each end connector 202 to
a respective end of the scaffold plank 200 is facilitated by the advancement
of the
fingers 230 of the end connector 202 into respective ones of the elongate
cavities
defined by the scaffold plank 200, such advancement terminating when the end
of the
scaffold plank 200 is abutted against the main body 220 of the engagement
portion
218 in the above-described manner. It is contemplated that each end connector
202
will be maintained in firm engagement to the scaffold plank 200 through the
use of
multiple fasteners such as screws 250. As seen in Figures 5 and 6, one pair of
screws
250 is advanced through respective ones of a pair of openings disposed within
one
side wall 208 of the scaffold plank 200 and into respective ones of a
complimentary
pair of internally threaded apertures 252 disposed within one of the outer
pair of
fingers 230 of the end connector 202. A second pair of screws 250 is extended
through openings in the remaining side wall 208 and into a complimentary pair
of
internally threaded apertures 252 disposed in the remaining finger 230 of the
outer
pair. Since the openings in the side walls 208 of the scaffold plank 200 are
disposed
within the bottom surfaces of respective ones of the slots 214, the heads of
the screws
250 do not protrude beyond the outermost surfaces of the upper and lower rails
210,
212 of each side wall 208, i.e., the heads of the screws 250 are effectively
contained
within respective ones of the slots 214. It is contemplated that the
mechanical
interlock between the end connectors 202 and scaffold plank 200 facilitated by
the
screws 250 may be supplemented by the application of an adhesive to prescribed
portions of each end connector 202 prior to the advancement of the attachment
fingers
230 thereof into the interior of the scaffold plank 200. Additionally, the
screws 250
may be omitted in their entirety as a result of the use of an adhesive.
Figures 8 and 9 depict the manner in which a pair of scaffold planks 2Q0
which each include the end connectors 202 attached to each of the opposed ends
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thereof are interfaced to a horizontal support bar 254 of a scaffolding
support frame
256. As seen in Figures 6, 8 and 9, the end connector 202 is engaged to the
support
bar 254 such that the arms 226 extend about the support bar 254. More
particularly,
the outer surface of the support bar 254 is abutted directly against the
arcuate body
surface 222 of the main body 220 and against the arms surfaces 228 of the arms
226.
Advantageously, since the body surface 222 spans the entire length of the main
body
220, the scaffold plank 200 is not susceptible to rocking or tipping when
weight or
downward force is applied to the longitudinal edges thereof.
Once one end connector 202 of one scaffold plank 200 is cooperatively
engaged to the support bar 254 in the above-described manner, one end
connector 202
of the remaining scaffold plank 200 is itself cooperatively engaged to the
same
support bar 254. In this regard, the arms 226 of the end connector 202 of one
scaffold
plank 200 are nested into respective ones of the notches 224 of the
corresponding end
connector 202 of the other scaffold plank 200 in the manner shown in Figure 9.
When the corresponding end connectors 202 of the scaffold planks 200 are
interfaced
to the common support bar 254 as shown in Figure 9, the contours of the top
surfaces
of the arms 226 results in the distal portions thereof being recessed
downwardly
relative to the top surfaces of the main bodies 220 of the engagement portions
218 of
the corresponding end connectors 202.
As seen in Figure 6, further in accordance with the present invention, it is
contemplated that each end connector 202 of each scaffold plank 200 may
optionally
be provided with a locking clip 258 which is preferably fabricated from a
resilient
metallic material (e.g., steel) and secured to the main body 220 of the
engagement
portion 218 via one or more fasteners such as screws 260. It will be
recognized that
each end connector 202 may be outfitted with one relatively large locking clip
258, or
multiple, smaller identically configured locking clips 258 disposed in spaced
relation
to each other. The locking clip 258 is sized and configured to frictionally
engage the
support bar 254 in the manner shown in Figure 6, thus inhibiting the easy
uplift of the
end connector 202 out of engagement to the support bar 254. Those of ordinary
skill
in the art will recognize that the inclusion of the locking clip(s) 258 are
optional, and
that alternative locking mechanisms may be included in each end connector 202
to
facilitate the secure connection thereof to the scaffolding support frame 256.
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Referring now to Figure 10, further in accordance with the present invention,
it is contemplated that the slots 214 included in the side walls 208 of each
scaffold
plank 200 may be used to accommodate edge connectors (not shown) which
effectively maintain two or more scaffold planks 200 in side-by-side
attachment to
5 each other, i.e., the longitudinal side wall 208 of one scaffold plank 200
is
cooperatively engaged to a corresponding side wall 200 of an adjacent scaffold
plank
200. In Figure 10, three scaffold planks 200 are shown in such side-by-side
engagement, with the end connectors 202 of each set of three interconnected
scaffold
planks 200 themselves being cooperatively engaged to a common horizontal
support
10 bar 254 of the scaffolding support frame 256. As further shown in Figure
10, it is also
contemplated that a corner connector 260 may be used in conjunction with two
interconnected sets of scaffold planks 200, the corner connector 260 being
sized and
configured to allow the interconnected sets of scaffold planks 200 to be
effectively
joined to each other, despite being disposed at a prescribed angular
displacement
15 relative to each other. As shown in Figure 10, the corner connector 260
includes an
opposed pair of side edges, each of which is formed to include an arcuate,
generally
concave engagement surface 262, a plurality of arms 264, and a plurality of
notches
266. The engagement surface 262, arms 264 and notches 266 of each side edge
are
structurally and functionally identical to the body surface 222, notches 224,
and arms
20 226 of each end connector 202. In this regard, when the end connectors 202
of the
interconnected scaffold planks 200 of one set are cooperatively engaged to the
common support bar 254, one side edge of the corner connector 260 may be
cooperatively engaged to the same support bar 254, with the arms 264 of the
corner
connector 260 being nested within respective ones of the notches 224 of the
interconnected scaffold planks 200, and the arms 226 of the interconnected
scaffold
planks 200 being nested within respective ones of the notches 266 of the
corner
connector 260.
The corner connector 260 is preferably fabricated from a plastic material via
an injection molding process, with the top surface of the corner connector 260
also
being provided with a roughened, non-slip texture. As seen in Figure 10, the
corner
connector 260 is sized to span approximately 30 , though those of ordinary
skill in the
art will recognize that the corner connector 260 may be formed to span
differing
angular intervals. Additionally, multiple corner connectors 260 may be
cooperatively
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engaged to the scaffolding support frame 256 proximate to each other so as to
collectively define a span of more than 30 . For example, two corner
connectors 260
as shown in Figure 10 disposed in side-by-side relation to each other would
span
approximately 60 , with three corner connectors 260 interlocked to the
scaffolding
support frame 256 in side-by-side relation to each other spanning
approximately 90 .
Though the corner connector 260 shown in Figure 10 is shown as being sized to
be
interfaced to two sets of three interconnected scaffold planks 200, the corner
connector 260 may alternatively be sized and configured to span between only
two
interconnected scaffold planks 200, or even individual scaffold planks 200
which are
angularly displaced relative to each other.
Refeiring now to Figures 11-16, there is shown a scaffold plank 300
constructed in accordance with a fourth embodiment to the present invention.
The
scaffold plank 300 is preferably outfitted with a pair of end connectors 302
which are
cooperatively engaged to respective ones of the opposed ends of the scaffold
plank
300. The structural and functional attributes of each end connector 302 (one
of which
is shown in Figures 13-15 as exploded from the scaffold plank 300) will be
described
in more detail below.
As best seen in Figure 16, the scaffold plank 300 is preferably a unitary
structure which defines a generally planar, sheet-like top wall 304 and a
generally
planar, sheet-like bottom wall 306. The top and bottom walls 304, 306 extend
in
spaced relation to each other along respective ones of a generally parallel
pair of
planes. Extending perpendicularly between corresponding pairs of the
longitudinal
edges of the top and bottom walls 304, 306 is a spaced, generally parallel
pair of side
walls 308. Though the inner surfaces of the side walls 308 are generally
planar, the
outer surfaces thereof each include an integral upper rail 310 and an integral
lower rail
312 extending longitudinally therealong in spaced, generally parallel relation
to each
other. The upper rails 310 extend along respective ones of the opposed
longitudinal
sides of the top wall 304, and are each substantially flush with outer surface
of the top
wall 304. Similarly, the lower rails 312 extend along respective ones of the
opposed
longitudinal sides of the bottom wall 306 and are each substantially flush
with the
outer surface of the bottom wall 306. Each of the upper and lower rails 310,
312
preferably defined a continuous slot or channel 314. The use of these channels
314
will be discussed in more detail below.
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The scaffold plank 300 further comprises a plurality of reinforcement walls
316 which extend perpendicularly between the inner surfaces of the top and
bottom
walls 304, 306. The reinforcement walls 316 extend longitudinally along the
length
of the scaffold plank 300 in spaced, generally parallel relation to each
other. Though
the reinforcement walls 316 are equidistantly spaced relative to each other,
the
spacing between the outermost pair of reinforcement walls 316 and respective
ones of
the side walls 308 is slightly increased in comparison to the spacing between
the
reinforcement walls 316. As a result, an outer pair of cavities collectively
defined by
the top and bottom walls 304, 306, outermost pair of reinforcement walls 316,
and
side walls 308 each have a width which is slightly greater than that of
multiple inner
cavities which are each collectively defined by the top and bottom walls 304,
306 and
an adjacent pair of the reinforcement walls 316. As seen in Figure 16, the
scaffold
plank 300 is formed to include four (4) reinforcement walls 316. As a result,
the
scaffold plank 300 includes three (3) inner cavities and two (2) outer
cavities which,
as indicated above, are of increased width as compared to the inner cavities.
However, those of ordinary skill in the art will recognize that the number of
reinforcement walls 316 included in the scaffold plank 300 as shown in Figure
16 is
exemplary only, in that greater or fewer reinforcement walls 316 may be formed
to
extend between the top and bottom walls 304, 306. Also exemplary is the
spacing
between the reinforcement walls 316, in that it is contemplated that the
reinforcement
walls 316 may be equidistantly spaced relative to each other and to the side
walls 308,
thus causing all of the cavities defined by the scaffold plank 300 to be of
equal size.
In the scaffold plank 300, a pair of apertures 317 is disposed within each of
the
side walls 308 and within each of the reinforcement walls 316. In Figure 16,
only one
aperture 317 of the pair included in each of the side walls 308 and each of
the
reinforcement walls 316 is shown, the remaining such aperture 317 being
located in
the same proximity to the opposite end of the scaffold plank 300 as the
depicted
aperture 317. Thus, the apertures 317 are provided in two sets, with the
apertures 317
of one set being disposed within the side walls 308 and reinforcement walls
316 in
equidistantly spaced relation to one end of the scaffold plank 300, and the
apertures
317 of the remaining set being disposed within the side walls 308 and
reinforcement
walls 316 in equidistantly spaced relation to the remaining, opposite end of
the
scaffold plank 300. As is apparent from Figure 16, the apertures 317 of each
set are
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also positioned in respective ones of the side and reinforcement walls 308,
316 so as
to extend in coaxial alignment with each other. The use of each coaxially
aligned set
of apertures 317 will be described in more detail below.
It is contemplated that the scaffold plank 300 of the fourth embodiment will
be
fabricated in its entirety from a non-metal material via an extrusion or
injection
molding process. Exemplary materials for the scaffold plank 300 include
various
types of plastics (e.g., glass-filled polyethylene), fiber reinforced
composites, or
combinations thereof. In this regard, it is further contemplated that the
extrusion
process preferably used to facilitate the formation of the scaffold plank 300
may be
carried out in a manner wherein various portions of the scaffold plank 300 are
fabricated from a fiber reinforced plastic or composite, with other portions
simply
being fabricated from a non-reinforced plastic material. More particularly,
depending
on the level of structural integrity desired for the scaffold plank 300, one
or more of
the reinforcement walls 316 may be fabricated from a fiber reinforced
composite
material, with the remainder of the scaffold plank 300 being fabricated from a
plastic
material. As indicated above, the extrusion process preferably used to
facilitate the
formation of the scaffold plank 300 may be completed such that the scaffold
plank
300 is a unitary structure, even if prescribed areas of the scaffold plank 200
are
fabricated from differing non-metallic materials. As a further variation, the
scaffold
plank 300 may be fabricated entirely from a non-reinforced plastic material,
with
reinforcing sheets of a fiber reinforced composite material being applied to
the outer
surface of the top wall 304 and/or the outer surface of the bottom wall 306
for
purposes of increasing the structural integrity/rigidity of the scaffold plank
300.
In the scaffold plank 300, the outer surface of the top wall 304 is preferably
formed to have a roughened or textured feature to provide the scaffold plank
300 with
non-slip characteristics. More particularly, it is contemplated that
prescribed areas of
the outer surface of the top wall 302 will be formed to include the roughened,
textured
feature, such feature being provided as three elongate textured strips 319
which
extend longitudinally along the outer surface of the top wall 304 in spaced,
generally
parallel relation to each other. In this regard, two of the textured strips
319 extend
along and in spaced relation to respective ones of the longitudinal sides or
edges of
the top wall 304, with the third, remaining textured strip 319 extending
substantially
intermediate the outer pair of textured strips 319. It is further contemplated
that each
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of the three textured strips 319 will be formed directly in the outer surface
of the top
wall 304 during the process of extruding the scaffold plank 300 by, embedding
three
separate strips of roughened fabric within the outer surface of the top wall
304
immediately upon the same exiting the extrusion die. Subsequent to the cooling
of
the non-metal material used to form the scaffold plank 300, the removal or
peeling of
the fabric strips from the top wall 304 result in the formation of the
textured strips 319
therein. Thus, due to the textured strips 3] 9 constituting part of the top
wall 304 as
opposed to a separate substance applied thereto, such textured strips 319 are
not
susceptible to chipping, flaking off or otherwise wearing away during normal
use of
the scaffold plank 300. Those or ordinary skill in the art will recognize that
the
inclusion of three textured strips 319 as shown in Figure 16 is exemplary
only, in that
the possible inclusion of greater or fewer textured strips 319 of greater or
lesser width
than that shown in Figure 16 is contemplated to be within the spirit and scope
of the
present invention. Those of ordinary skill in the art will also recognize that
the non-
skid, roughened texture described above may also be included on the outer
surface of
the bottom wall 306.
As indicated above, the scaffold plank 300 of the fourth embodiment further
includes a pair of end connectors 302 cooperatively engaged to respective ones
of
each of the opposed ends thereof. Each end connector 302 includes an
engagement
portion 318 having a main body 320 which defines an arcuate, generally concave
body surface 322. The body surface 322 spans approximately ninety degrees.
Formed within the main body 320 is a spaced pair of notches 324, each of which
defines an arcuate, concave apex. In addition to the main body 320, the
engagement
portion 318 of the end connector 302 includes a spaced, identically configured
pair of
arms 326 which are integrally connected to the main body 320. Each of the arms
326
defines an arcuate, generally concave arm surface 328 which, like the body
surface
322, also spans approximately ninety degrees. The main body 320 and arms 326
are
oriented relative to each other such that one of the notches 324 is disposed
between
the arms 326, with the remaining notch 324 being disposed between one arm 326
and
one lateral end of the main body 320. Importantly, the main body 320 and arms
326
are oriented relative to each other such that the arms surfaces 328 of the
arms 326 are
continuous with the body surface 322 of the main body 320. Thus, the arms
surfaces
328 and portions of the body surface 322 collectively define engagement
surfaces
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which span, in total, approximately 180 . As seen in Figure 15, the side walls
of the
arm 326 oriented between the notches 324 is continuous with the side walls of
such
notches 324. One side wall of the remaining arm 326 is continuous with the
side wall
of the notch 324 disposed between the arms 326. As also seen in Figure 15, due
to the
5 shape of the engagement portion 318 of each end connector 302, the depth of
the
notch 324 located between the arms 326 appears to be greater than that of the
remaining notch 324 due to the side wall of the notch 324 between the arms 326
being
continuous with one side wall of each of the arms 326.
In addition to the engagement portion 318, each end connector 302 includes a
10 plurality of elongate, identically configured attachment fingers 330 which
protrude
perpendicularly from the side of the main body 320 opposite that including the
body
surface 322 formed therein. The fingers 330 extend in spaced, generally
parallel
relation to each other. As shown in Figures 13-15, five (5) attachment fingers
330 are
depicted as protruding from a common side of the main body 320. As is best
seen in
15 Figures 13 and 14, the fingers 330 are sized and configured to be
advanceable into
respective ones of the cavities defined by the scaffold plank 300. Disposed
within
each of the attachment figures 330 is a coaxially aligned set of apertures
331. In this
regard, the apertures 331 are positioned within each of the attachment figures
330
such that the apertures 331 of each set, in addition to being coaxially
aligned with
20 each other, are also coaxially aligned with the apertures 331 of each
remaining set
thereof. The advancement of the fingers 330 into respective ones of the
cavities is
limited by the abutment of a peripheral portion of the surface of the main
body 320
from which the attachment fingers 330 extend against corresponding lateral
edges of
the top and bottom walls 304, 306 and side walls 308 of one end of the
scaffold plank
25 300, in the manner shown in Figures 11 and 12. Importantly, when each end
connector 302 is fully advanced into a respective end of the scaffold plank
300 in the
aforementioned manner such that the main body 320 is abutted against the
scaffold
plank 300, all of the coaxially aligned apertures 331 of the end connector 302
will
further be coaxially aligned with the apertures 317 of that set adjacent the
end of the
scaffold plank 300 into which the end connector 302 is inserted. Thus, upon
the full
insertion of the end connectors 302 into respective ones of the opposed ends
of the
scaffold plank 300, all of the apertures 331 of each end connector 302, in
addition to
being coaxially aligned with each other, are also coaxially aligned with one
set of the
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apertures 317. Though each end connector 302 is depicted as including five (5)
attachment fingers 330 as described above, those of ordinary skill in the art
will
recognize that end connectors 302 having greater or fewer attachment fingers
330 are
contemplated to be within the spirit and scope of the present invention, the
precise
number of attachment fingers 330 being dependent upon the corresponding number
of
cavities defined by the scaffold plank 300.
It is contemplated that each end connector 302 will be fabricated from a
plastic material via an injection molding process, with the attachment fingers
330
being integrally connected to the main body 320 of the engagement portion 318.
As
best seen in Figure 15, it is further contemplated that the structural
integrity of each
end connector 302 may optionally be increased through the inclusion of a
reinforcement plate 344 therein. The reinforcement plate 344 is preferably
fabricated
from a metal material (e.g., steel), and has a shape which is complimentary to
that of
the main body 320, arms 326, and fingers 330. Though not shown, like the
] 5 reinforcement plate 244 described above, the reinforcement plate 344
includes a
plurality of reinforcement fingers which are sized and configured to be
advanceable
into the interiors of respective ones of the attachment fingers 330.
Additionally, the
reinforcement plate 344 includes a pair of arcuate reinforcement arms which
are
extensible into the interiors of respective ones of the arms 326. Since the
end
connector 302 is preferably fabricated via an injection molding process, it is
contemplated that the reinforcement plate 344 will initially be included in
the mold
cavity, with the plastic material used to form the remainder of the end
connector 302
being injected into the mold cavity in a manner effectively encapsulating the
reinforcement plate 344 in the manner similar to that shown in Figure 6 in
relation to
an end connector 202.
As indicated above, the cooperative engagement of each end connector 302 to
a respective end of the scaffold plank 300 is facilitated by the advancement
of the
fingers 330 of the end connector 302 into respective ones of the elongate
cavities
defined by the scaffold plank 300, such advancement terminating when the end
of the
scaffold plank 300 is abutted against the main body 320 of the engagement
portion
318 in the above-described manner. It is contemplated that each end connector
302
will be maintained in firm engagement to the scaffold plank 300 through the
use of an
elongate connector pin 350 which is shown in Figure 17. As shown, the pin 350
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includes an enlarged, button-like head 352 which is formed at one end thereof.
That
end of the connector pin 350 opposite the head 352 defines a juxtaposed pair
of ear
portions 354 which are separated from each other by an elongate slot 356.
Extending
laterally outward from the distal end of each ear portion is an integral
flange portion.
The pin 350 is fabricated from a plastic material of sufficient resiliency
such that the
ear portions 354 thereof may be selectively flexed inwardly into contact with
each
other.
To facilitate the attachment of each end connector 302 to the scaffold plank
300, one pin 350 is advanced through the coaxially aligned apertures 331 of
the end
connector 302, and the coaxially aligned apertures 317 of the corresponding
set of the
scaffold plank 300. The advancement of the pin 350 through such coaxially
aligned
apertures 317, 331 is continued until such time as the head 352 of the pin 350
is
abutted against the outer surface of one of the side walls 308 of the scaffold
plank
300. Advantageously, the pin 350 is sized such that once the abutment of the
head
352 against one side wall 308 occurs, the flange portions of the ear portions
354 at the
opposite end of the pin 350 will protrude from the opposite, remaining side
wall 308,
and flex outwardly into engagement with the outer surface of such side wall
308 in a
manner preventing the pin 350 from easily being removed from within the
coaxially
aligned apertures 317, 331. In the event that any, end connector 302 is to be
separated
from the scaffold plank 300, the flange portions of the ear portions 354 of
the
corresponding pin 350 may be severed through the use of an appropriate cutting
tool,
thus allowing the pin 350 to be removed from within the coaxially aligned
apertures
317, 331, and further allowing the end connector 302 to be separated from the
scaffold plank 300. Thus, the pins 350 are intended to be sacrificial, with
the re-
attachment of the end connector 302 to the scaffold plank 300 being achieved
by
advancing a new pin 350 into the coaxially aligned apertures 317, 331.
In the scaffold plank 300 including the end connectors 302, the manner in
which the such assembly is cooperatively engaged to a scaffolding support
frame
occurs in the same manner described above in relation to Figures 8 and 9
regarding
the engagement of the scaffold planks 200 including the end connectors 202 to
the
scaffolding support frame 256. The channels 314 included in the side walls 308
of the
scaffold plank 300 may be used to accommodate edge connectors which
effectively
maintain two or more scaffold planks 300 in side-by-side attachment to each
other,
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i.e., the longitudinal side wall 308 of one scaffold plank 300 is
cooperatively engaged
to a corresponding side wall 308 of an adjacent scaffold plank 300. Moreover,
it is
further contemplated that a corner connector similar to the corner connector
260
shown and described above in relation to Figure 10 may be used in conjunction
with
the scaffold planks 300 including the end connectors 302 when such scaffold
planks
300 are placed side-by-side.
Additional modifications and improvements of the present invention may also
be apparent to those of ordinary skill in the art. In this respect, the planks
formed in
accordance with the present invention may be used in applications other than
for
scaffolding. Thus, the particular combination of parts described and
illustrated herein
is intended to represent only certain embodiments of the present invention,
and is not
intended to serve as limitations ofalternative devices within the spirit and
scope of the
invention.
