Note: Descriptions are shown in the official language in which they were submitted.
CA 03061997 2019-10-21
WO 2018/200849
PCT/US2018/029615
IMPROVED SCAFFOLD PLANKS
Cross-Reference to Related Application
This application claims the priority benefit of U.S. Provisional Application
62/490,908 filed April 27, 2017, which is incorporated by reference herein in
its entirety.
Background
A scaffold frame is an interconnected series of horizontal vertical scaffold
members
and vertical scaffold members used to create a supporting structure for an
elevated work
surface. The horizontal and vertical scaffold members are generally pipe
shaped members
(circular or square in cross section, for instance) where the ends of each
horizontal scaffold
member terminates in connectors that attaches to a vertical scaffold members.
The connectors
can be clamp members (such as in tube and clamp scaffolding, see for instance,
Figure 1) or
more complex connectors, such scaffolding where an end connector positioned on
the end of
a horizontal member, where the end connector has a lip or hook section that
couples with a
structure on a vertical scaffold member. The lip sections are designed to
engage or rest on
the corresponding vertical joint connector, such as an upstanding cup or an
annular
ring positioned on a vertical scaffold member. One such joint is disclosed in
U.S. patent
number 4,445,307, which discloses a connector positioned on a horizontal
scaffold member,
where the connector has two vertically spaced hook sections.
Another cup type of latching connector is disclosed in U.S. patent numbers
5,078,532 and 5,028,164 and in U.S. application number 12/489,166 all hereby
incorporated by reference. These patents also show an end connector positioned
on a
horizontal scaffold member, where the connector has two vertically spaced
hooked sections
that couple with two vertically spaced upstanding cup or ring members located
on the
vertical scaffold member. In this device, the hooked sections engage the top
edge of the cup,
and a pivoting member or latch, positioned on the horizontal end connector, is
pivoted
into position below the cup member.
Instead of upstanding cups, a flat annular ring with openings in the ring may
be
used as the vertical connector on the vertical scaffold member, to couple to a
connector on a horizontal scaffold member. Examples of annular ring/connector
systems are
shown in U.S. patent numbers 4,273,463; 6,027,276; 5,961,240; 5,605,204;
4,840,513; all of
1
CA 03061997 2019-10-21
WO 2018/200849
PCT/US2018/029615
which are hereby incorporated by reference. These systems are generally
referred to
as wedge or pinlock scaffold systems. The pinlock system relies upon a wedge
or pin
being slidable (generally hammer driven) through the horizontal end connector
and
rosette. The above "system" scaffolds require a horizontal member to couple to
a
vertical member, that is, a horizontal member cannot couple to another
horizontal
member.
Once a scaffold frame is erected, an elevated work surface is created by using
scaffold boards that are supported at each end of the board by horizontal
scaffold frame
members. Typically, scaffold boards or planks are wooden, fiberglass, or metal
board-like
members, having a length (such as 10 feet) and a width, such as 9 inches. A
scaffold board
generally comprises a top surface, such as 6 inch, 9 inch, 12 inch, or 18 inch
wide board, and
come in various lengths, such as 2 feet long to 10 to 16 feet long. A typical
metal scaffold
board is shown in Figure 2, showing a metal plank 1, having a top surface 40,
and two side
rail extensions 70 extending downwardly at about 90 degrees to the top surface
1 adjacent the
edges of the top surface. The top surface 40 can be a solid surface, a surface
with drain holes,
or formed from a series of metal plates (see Figure 3). The scaffold plank
side rails 70 may
be integrally formed with the top surface (such as by roll forming the plank
from a single
piece of metal), or may be separately attached, such as by welding, riveting,
etc. Each metal
board top surface has two terminating ends, (a first terminating end edge 202
and a second
terminating end edge 204 (not shown)). The edge is linear, but may be curved.
Also shown
in Figure 2, the board 10 has a first top side edge 212 and a second top side
edge 214.
Located near each terminating end edge 204, 206 is at least one (preferably
two or more) clip
members 50. As shown in Figure 2, one embodiment of clip members 50 are shaped
plate
members with a downwardly facing channel 52 rearward of downward lip section
51. The
channel 52 is shaped to engage a horizontal scaffold member in a channel 52 or
cutout
section (not shown). As shown, the clips are vertical orientated plate
members, one attached
to each side rail 70. The clips can be "L" shaped member, "U" or "C" or other
"hook" type
of engagement members. In the embodiment shown in Figure 2, each clip 50 has a
leading
downward facing lip portion 51 (forming a hook-like structure) and a downward
facing
channel 52 behind the lip, together forming a "U" shaped clip or cleat 50. The
channel 52 is
located between the lip 51 and the adjacent terminating edge 202 or 204 of the
scaffold
board. The channel 52 may end before the respective terminating end edge 202
or 204, or at
the terminating end edge, or in other embodiments, behind the terminating end
edge.
2
CA 03061997 2019-10-21
WO 2018/200849
PCT/US2018/029615
When a scaffold board 10 is placed in a scaffold structure, the clip channel
52 will rest
or engage a horizontal scaffold member, thereby supporting the scaffold plank
10. The clips
50 can be vertical orientated plates, such as shown in Figure 2, or the clip
plates 50 may be
substantially horizontally oriented formed or shaped plates, such as shown in
Figure 4, or the
clips may be square or circular or other shapes in cross section to couple
with a horizontal
scaffold member or another scaffold plank. The scaffold elevated work surface
generally
forms a continuous uninterrupted surface, with safety railing surrounding the
work deck or
work surface. Often however, the elevated surface may have to be constructed
around a
structure or obstacle. For instance, pipes, chimneys or conduits may need to
extend through
the work deck. An obstruction that penetrates through the deck of a scaffold
deck will leave
an opening in the deck, where the length of the opening corresponds to that of
the adjacent
scaffold board, as depicted in Figure 5, a top view of a deck with a conduit
extending
through the deck area. To close the resulting opening, often wooden scaffold
boards are used
across the opening, where the boards are placed across the metal planks (for
instance, at 90
degrees to the metal planks). However, the wooden planks are a tripping
hazard.
Alternatively, two "interior" horizontal scaffold members can be positioned in
the
interior of the frame, on opposite sides of the obstruction (which will
require additional
vertical members, as the horizontal members generally couple to a vertical
scaffold member.
particularly in system scaffolding). Note, however, the "additional vertical
scaffold member"
can be an intermediate scaffold joint, one embodiment of which is as disclosed
in U.S. patent
number 8,973,711, hereby incorporated by reference in its entirety, to create
a frame structure
to allow placement of short scaffold planks at right angles to the existing
scaffold planks, to
thereby close the opening created by the obstacle. This is depicted in Figure
6 and Figure 7.
A better system is needed to accommodate openings in scaffold decks.
Brief Description of the Drawings
Figure 1 is a cartoon perspective of a scaffold system with elevated deck.
Figure 2 is a side perspective view of a prior art high profile scaffold
board.
Figure 3 is top perspective view of another prior art high profile scaffold
board.
Figure 4 is a top perspective view of one end of one embodiment of the
improved low profile
scaffold boards.
Figure 5 is a top view of a scaffold decking penetrated by an obstacle.
Figure 6 is a top view of a scaffold decking of figure 5 with intermediate
horizontal scaffold
members laid in the perimeter of the opening.
3
CA 03061997 2019-10-21
WO 2018/200849
PCT/US2018/029615
Figure 7 is a top view of a scaffold decking of figure 6 with scaffold planks
laid across and
supported by the intermediate horizontal scaffold members.
Figure 8 is a top perspective view of one embodiment of an improved low
profile scaffold
board.
Figure 9A is a side elevation view of one end of the scaffold board of figure
8.
Figure 9B is a side elevation view of two scaffold boards as in figure 8
coupled together in a
side-to-end configuration.
Figure 9C is a top elevation view of one end of the scaffold board of figure
8.
Figure 10 is a top perspective view of a cross section through the scaffold
board of figure 8.
Figure 11A is a top elevation view of another embodiment of the improved
scaffold board.
Figure 11B is a side elevation view of the scaffold board of figure 11A.
Figure 11C are side elevation views of different embodiments of low profile
clips.
Figure 11D are end views of the scaffold board of figure 11A, with 11D-1
showing an end
view of the top portion, 11D-3 showing an end view of the bottom portion, and
11D-2
showing an end view of the assembled bottom and top portion.
Figure 11E is a side elevation view of two of the scaffold boards of figure 11
coupled
together in an end-to-side configuration.
Figure 12 is a perspective view depicting an embodiment of the improved boards
in aside-
to-end configuration around an obstacle.
Figure 13 is a top perspective view of a scaffold deck depicting joining a
series of scaffold
members (10-1 through 10-7) to two adjacent improved scaffold members (10-C
and 10-D)
in a side to end configuration.
Figure 14A is a top elevation view of another embodiment of the improved
scaffold board (a
high profile configuration).
Figure 14B is a side elevation view of the scaffold board of figure 14A.
Figure 14C are side elevation views of different embodiments of high profile
clips.
Figure 14D are end views of the scaffold board of figure 14A, with 14D-1
showing an end
view of the top portion, 14D-3 showing an end view of the bottom portion, and
14D-2
showing an end view of the assembled bottom and top portion.
Figure 14E is a side elevation view of two of the scaffold boards of figure 14
coupled
together in an end-to-side configuration.
4
CA 03061997 2019-10-21
WO 2018/200849
PCT/US2018/029615
Detailed Description of the Invention
The invention is an improved scaffold plank. As shown in the view of Figure 8,
one
embodiment of the plank is a board like member 10, having a first and second
terminating
ends 202, 204, first and second side edges 212, 214, a top surface 40
extending between the
two terminating ends and two side rails 70, extending downwardly from the top
surface at
about 90 degrees, running substantially the length of the board 10, and are
positioned on the
scaffold board near the side edges 202 and 214. Positioned at or near
terminating ends 202,
204 is at least one shaped clip 50, shaped to couple with a horizontal
scaffold member.
Generally, the clips are "L," "U" or "C" shaped plates extending outwardly
from the
terminating ends of the plank 10. As shown in Figure 8, the clips 50 are
attached to an end
brace 60 that extends between the side rails 70 of the plank 10. The clips 50
could also be
attached to the top surface 40, or side rails 70, or be integrally formed with
the top surface or
rails. In the embodiment shown, the clips 50 are flat metal plates bent in a
"U" shape,
where the plate is orientated substantially horizontally (as opposed to
orientated in a vertical
orientation, such as shown in Figure 2). The horizontal orientation of the
clip 50, where the
top of plate above the channel 52 is approximately at the height of the top
surface 40 of the
plank, allows for the top surface 40 of the plank to closely align with the
top surface of a
supporting horizontal member, such as shown in Figure 9A. The top surface 40
shown is
formed from a metal plate, such as 16 gauge steel, with drain holes there
through.
As can be seen in Figure 8, in one embodiment, the clips 50 on opposite
terminating
ends are not aligned, but are offset to accommodate placement of scaffold
boards "end-to-
end" lengthwise on the same horizontal scaffold member. On each terminating
end 202 and
204, one clip 50A is positioned near a side rail 70, while the other clip SOB
is offset and
interior to the board from the opposing side rail 70. Also shown is optional
tab 90, which
projects from the top surface of the board 40, and has a thickness of a clip.
The tab 90 is
placed near the inward clip SOB, to resist rotation of the board on the
supporting horizontal
scaffold member of supporting board member. Tab 90 is positioned so not to
interfere or
overlap with an adjacent scaffold board clip when placed end-to-end lengthwise
or in an end-
to side configuration shown in Figure 10.
As shown in the embodiment of Figure 8, side rails 70 are positioned adjacent
the top
surface 40 near the first and second top side edges 212, 214 to provide
stiffening or a truss
like component to the board 10. In one embodiment, shown in Figure 10, the
side rails 70
are shaped frame members, shaped with a bottom facing foot 71. Each side rail
70 has at least
5
CA 03061997 2019-10-21
WO 2018/200849
PCT/US2018/029615
one outward facing surface 75, and one inward facing surface 76. The side
rails 70 can be
integrally formed with the top surface 40, such as by roll forming, or the
side rail 60 may be
attached to the top of the plank 40, such as by welding or with rivets or
other mechanical
attachment means. The side rails 70 can be a more complex assembled structure
having
multiple "rails" or shaped metal pieces, with multiple inward facing surfaces
76 and multiple
outward facing surfaces 75, such as shown in Figure 11. As shown in his cross
section, the
board is of two piece construction. The top 40 of the board 10 is formed with
first downward
side rails, 70A (Figure 11A). The bottom of the board, 43, is a second piece,
formed with
second upward side rails 70B (Figure 11B). The top and bottom are combined in
the
assembled board 10 (shown in Figure 11C), such as by welding the top piece to
the bottom
piece. As shown in Figure 8, the side rails 70 may also have openings 79
therethrough. The
openings 79 reduce the weight of the board 10. If openings 79 are included in
the side rails
70, preferably the openings 79 are suitably sized to allow for placement of a
"slick tube" (a
smooth tubular member lacking typical horizontal end connectors) through the
openings, so
that adjacent boards can be coupled with the slick tube, providing additional
strength and
stiffness to the decking formed from the scaffold boards.
The top surface 40 of the scaffold board 10 also has a series of openings or
slots 100.
In the embodiment shown in Figure 8, the slots 100 are placed near but offset
from the top
side edges of the board, generally with at least a portion of the slot 100
extending inwardly
(or behind) at least outwardly facing surface 75 of the side rails. In the
embodiment shown,
the slots 100 are aligned parallel with the side rails 70. The slots 100 in
this embodiment are
located at a specific distance inward from the top edges of the board, and
sufficiently sized to
allow placement of a clip 50 of a second scaffold board, orientated at 90
degrees, through a
slot 100, as shown in Figure 9B. In this configuration, two boards are coupled
together in an
"end-to-side" configuration, with the "end" of one board coupled to the "side"
of a second
board, allowing for two boards to be coupled to each other at about 90
degrees, without an
intervening horizontal scaffold member. As shown in this figure, the slot 100
in this
embodiment is orientated so that the lip 51 of the clip 50 of the second board
extends through
the slot, and the channel cut out of the second board is supported by the
first scaffold board's
top surface 40. The slots 100 are configured to allow such board-to-board
coupling, where the
coupled boards are orientated at 90 degrees to one another with the top
surface of the coupled
boards being adjacent, but preferably not overlapping. As shown in Figure 12,
one board
10B is coupled to an adjacent board 10A, at 90 degrees to board 10A, where the
clips 50 on
board 10B mate with slots 100 on board 10A. This board-to-board coupling does
not require
6
CA 03061997 2019-10-21
WO 2018/200849
PCT/US2018/029615
an intervening horizontal member (such as would otherwise be required, as
shown in Figure
7).
As shown in Figure 13, a decking can be formed by coupling some board members
to
horizontal scaffold members (board 10-A, 10-B, 10-C and 10-D), while coupling
other
boards (10-1, 10-2, 10-3, 10-4, 10-5, 10-6 and 10-7) at 90 degrees to certain
(boards 10-C
and 10-D) of the boards supported by horizontal scaffold members. As shown in
Figure 12,
such board¨to-board coupling allows for placement of a scaffold structure
around
obstructions, such as pipes 1000. In the embodiment shown in Figure 9B, the
coupled board
10B top surface is slightly higher than the adjoining board 10A top surface.
These surfaces
can be aligned if the side edge of the board 10A, immediately adjacent the
openings 100, are
formed (such as by roll forming) to be slightly depressed from the top surface
40 of the board
(depressed the thickness of the clip plate 50, for instance). The improved
scaffold boards can
be combined with existing scaffold boards, or used alone, to create scaffold
decking. The
placement of the clips 50 on the end edges of each board can be varied, and
the number of
.. clips can be varied. As shown, the slots 100 are uniformly distributed, but
this also can be
varied. For instance, a board may have one terminating end containing three
clips spaced in
the center of a board, while the other terminating end of the board has two
clips located near
opposing side rails. The openings or slots 100 in the plank do not have to be
uniformly
spaced, but are located and spaced to couple with the respective clips. In
certain
embodiments, slots 100 may also be present in the ends of the boards to
accommodate end-
to-end placement, such as shown in the embodiment shown in Figure 14, later
described.
If the board is constructed with clips 50 positioned vertically on the side
rails (such as
shown in Figure 2), the desired openings or slots 100 in the top portion of
the board may be
slots that start at the board side edge, and extend from the edge inwardly
toward the center of
the board, such as shown in Figure 14 and 11)(Figure 14 shows a high profile
board, while
Figure 11 shows a low profile board). In these two embodiments, the clips on
the high
profile board are vertically oriented plates, while the clips on the low are
also vertical plates
but of thicker material, as the top of the clip above the channel is thinner,
but must still be
sufficiently strong to support the scaffold board. Instead of plates, the
clips could also be
formed from square or rectangular rods. As shown in this embodiment in Figures
14E and
11E, the cleats or clips 50 on the board supported board 10A extend partially
through the side
rail 70 of the supporting board 10B, through the slide slits 100 on the
supporting board. The
slots 100 partially extend through the side rail 70, but generally, not
completely through the
side rail 70, as the side rail 70 (or a portion thereof) will support the
coupled board, as
7
CA 03061997 2019-10-21
WO 2018/200849
PCT/US2018/029615
depicted in Figures 14E and 11E. The side rail, as shown, has an inverted or
upside down
"L" shape, (both sides therefore forming a "T" shaped board in cross section)
where the leg
of the L is positioned near the top surface of the board. The height of this
top leg of the L
should preferably closely match the height of a clip above the associated
channel plus the
thickness of the top surface. This height allows a side to end configuration
to have the two
adjoining top surfaces of the boards to be level or almost level with each
other. The length of
the top leg of the L should closely match the length of the channel of a clip
from the inner
edge of the downwardly projecting lip to the adjoining end edge of the
associated board. This
length allows two boards, in a "side to end configuration" to be positioned so
that the side
edge of the supporting board is almost immediately adjacent to the end edge of
the supported
board. That is, the two top surfaces of the boards will be adjacent, with only
a small gap
between the boards in a side to end configuration. Proper dimensioning allows
a clip to rest
on the side wall and allow the two top surfaces to be closely aligned. Using
one or more
pieces, such as the top and bottom pieces shown in Figures 14D and 15D,
provides strength
and rigidity to the side rail to assist to support a board on such side rails.
Details of these boards are shown in the remaining portions of Figures 14 and
11.
For instance. As shown in Figure 14D, the board 10 is formed from a top piece
200 and a
bottom piece 300. Both top and bottom pieces have side rail extension portions
70. On the
top piece 100, the side rail extension 70 includes a ledge portion 77 where
the side rail
portion bends inwardly 80 degrees. The slots 100 in the top of the board
extend through the
top side rail portion, but preferably not through the bottom side rail
portion. When a board
supports another board in an end-to-side configuration, the side supported
board's clips will
extend through the slots in the supporting board, to terminate and rest (and
be supported by)
the ledger 77, as shown in Figure 14E.
When vertical clips are used, the two terminating ends of the scaffold board
may be
mirror images, or almost mirror images, as the offset needed for horizontal
clips is not
required for end-to-end positioning. See Figures 14A and 11A. As shown, the
terminating
ends, 204 and 202 are also shown with slots 100. These terminating slots allow
two boards,
placed in an end-to end relationship (where both boards are supported by the
same horizontal
scaffold member), to have the adjoining top surfaces 40 located adjacent to
each other with
little or no gap between the adjoining boards (not shown).
To assemble boards in a side-to-end configuration in an existing scaffold
frame
structure, a first scaffold plank utilizing the slotted openings is positioned
in a scaffold
structure, supported on each of its terminating ends by opposing horizontal
scaffold members.
8
CA 03061997 2019-10-21
WO 2018/200849
PCT/US2018/029615
A second scaffold plank (which may lack the slotted openings 100, but has end
clips 50) is
positioned at 90 degrees to the first scaffold plank, with the clips at a
first end of the second
board positioned above corresponding slots 100 of the first scaffold board
(i.e., those slots
along the side edge of the first board). The second scaffold board is lowered,
so that the clips
at the first end of the second board partially pass through the aligned slots
or openings in the
first board, until the first end of the second scaffold board member is
supported by the first
scaffold board. One end of the second board is now coupled to, and supported
by, the first
board, without an intervening horizontal member between the first and second
board
members. The clips on the second end (the distal end) of the second board may
be supported
by a another horizontal scaffold member, or supported by a third scaffold
board orientated 90
degrees to the second scaffold board, with the third scaffold board having
slots that align with
the clips at the second terminating end of the second scaffold board.
While the illustrative forms disclosed herein have been described with
particularity, it
will be understood that various other modifications will be apparent to and
can be readily
made by those skilled in the art without departing from the spirit and scope
of the disclosure.
For instance, the improved board may have only a single side adapted with
slots to support a
board in a side to end configuration. Accordingly, it is not intended that the
scope of the
claims appended hereto be limited to the example and descriptions set forth
herein, but rather
that the claims be construed as encompassing all the features of patentable
novelty which
reside herein, including all features which would be treated as equivalents
thereof by those
skilled in the art to which this disclosure pertains.
When numerical lower limits and numerical upper limits are listed herein,
ranges
from any lower limit to any upper limit are contemplated.
9
