Note: Descriptions are shown in the official language in which they were submitted.
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LADDER
Cross-Reference to Related Patent Applications
[0001] The present application claims priority to: (1) United State
Provisional Patent Application
Serial No. 62/865,185, filed June 22, 2019; and (2) United State
Nonprovisional Patent
Application Serial No. 16/219,834, filed December 13, 2018, the entireties of
which are
incorporated herein by reference.
Background of the Invention
[0002] Conventional straight ladders and step ladders have left and right side
rails and a plurality
of rungs rigidly attached between the side rails. Such conventional ladders
occupy a substantial
amount of space due to the large open spaces between the rungs and the rails.
It can be very
difficult for persons without access to a large truck to transport such
conventional ladders from
one place to another, including transporting such a ladder home from a brick-
and-mortar store at
which it may be purchased. Furthermore, conventional ladders make it difficult
if not impossible
to access older homes and structures due to narrow staircases or other
obstructions preventing
access. Thus, there is a need for a ladder that can be folded and collapsed to
reduce its size for
storage and transport without affecting the stability and usability of the
ladder.
Summary of the Invention
[0003] In one aspect, the invention can be a ladder comprising: a first ladder
section comprising:
a first side rail extending along a first axis; a second side rail extending
along a second axis; a
plurality of first rungs having a first end pivotably coupled to the first
side rail and a second end
pivotably coupled to the second side rail; a first handle on the first side
rail; and a second handle
on the second side rail; and the first ladder section alterable, by folding
the second side rail
relative to the first side rail to cause pivoting about the first and second
ends of the plurality of
first rungs, between: (1) a load bearing ladder state in which the first and
second handle are
offset from one another in an axial direction; and (2) a rail-to-rail
collapsed state in which the
first and second side rails are adjacent one another and the first and second
handles are at least
partially aligned with one another in the axial direction.
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[0004] In another aspect, the invention can be a ladder comprising: a first
ladder section
comprising: a first side rail extending along a first axis; a second side rail
extending along a
second axis; a plurality of first rungs having a first end pivotably coupled
to the first side rail and
a second end pivotably coupled to the second side rail; a locking assembly
alterable between: (1)
a locked state in which the first ladder section is locked in a load bearing
ladder state; and (2) an
unlocked state in which the second side rail can be folded relative to the
first side rail to alter the
first ladder section between the load bearing ladder state and a rail-to-rail
collapsed state; a user-
operated actuator located on the second side rail and operably coupled to the
locking assembly to
alter the locking assembly from the locked state to the unlocked state upon a
force being applied
to the user-operated actuator in an upward axial direction moving from a
bottom end of the
second side rail toward a top end of the second side rail; and wherein, upon
the locking assembly
assuming the unlocked state, continued application of the force to the user-
operated actuator in
the upward axial direction causes pivoting about the first and second ends of
the plurality of first
rungs to cause the second side rail to lift and fold toward the first side
rail, thereby altering the
first ladder section from the load bearing ladder state to the rail-to-rail
collapsed state.
[0005] In yet another aspect, the invention can be a ladder comprising: a
first ladder section
comprising: a first side rail extending along a first axis; a second side rail
extending along a
second axis; a plurality of first rungs having a first end pivotably coupled
to the first side rail and
a second end pivotably coupled to the second side rail; a locking assembly
alterable between: (1)
a locked state in which the first ladder section is locked in a load bearing
ladder state; and (2) an
unlocked state in which the second side rail can be folded relative to the
first side rail to alter the
first ladder section between the load bearing ladder state and a rail-to-rail
collapsed state; a user-
operated actuator alterable between a first state and a second state, the user-
operated actuator
operably coupled to the locking member to alter the locking assembly from the
locked state to
the unlocked state when altered from the first state to the second state; a
first resilient element
that biases the user-operated actuator into the first state; and a second
resilient element that
biases the locking assembly into the locked state.
[0006] In a further aspect, the invention can be a ladder comprising: a first
ladder section
comprising: a first side rail extending along a first axis; a second side rail
extending along a
second axis; and a plurality of first rungs having a first end pivotably
coupled to the first side rail
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and a second end pivotably coupled to the second side rail; a first locking
assembly alterable
between: (1) a locked state in which the first ladder section is locked in a
load bearing ladder
state; and (2) an unlocked state in which the second side rail can be folded
relative to the first
side rail to alter the first ladder section between the load bearing ladder
state and a rail-to-rail
collapsed state; a first user-operated actuator located on the second side
rail and operably
coupled to the first locking assembly to alter the locking assembly from the
locked state to the
unlocked state; a second ladder section comprising: a third side rail
extending along a third axis;
a fourth side rail extending along a fourth axis; and a plurality of second
cross-members
extending between and coupled to the third side rail and the fourth side rail;
a second locking
assembly alterable between: (1) a locked state in which the second ladder
section is locked in a
second ladder state; and (2) an unlocked state in which the fourth side rail
can be folded relative
to the third side rail to alter the second ladder section between the ladder
state and a rail-to-rail
collapsed state; a second user-operated actuator located on the second side
rail and operably
coupled to the second locking assembly to alter the second locking assembly
from the locked
state to the unlocked state; a pair of hinges pivotably coupling the first and
second ladder
sections to one another, the pair of hinges adjustable between and lockable in
a plurality of
selectable angular configurations when each of the first and second ladder
sections are in a load
bearing state, the selectable angular configurations comprising: at least one
of: (i) a straight
ladder configuration in which the third axis of the third side rail is
substantially coaxial with the
first axis of the first side rail and the fourth axis of the fourth side rail
is substantially coaxial
with the second axis of the second side rail; and (ii) a step ladder
configuration in which a first
acute angle is formed between the first axis of the first side rail and the
third axis of the third side
rail and a second acute angle is formed between the second axis of the second
side rail and the
fourth axis of the fourth side rail; and a folded configuration in which the
first and third side
rails extend adjacent one another and the second and fourth side rails extend
adjacent one
another so that the first and second user-operated actuators are at least
partially aligned with one
another in an axial direction.
[0007] In an even further aspect, the invention can be a ladder comprising: a
first ladder section
comprising: a first side rail and a second side rail; a plurality of non-
locking first rungs having a
first end pivotably connected to the first side rail and a second end
pivotably connected to the
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second side rail; at least one locking rung having a first end pivotably
connected to the first side
rail and a second end pivotbaly connected to the second side rail, the at
least one locking rung
comprising a track; a locking assembly comprising: a locking bar slidably
coupled to the locking
rung within the track; a locking member pivotably coupled to at least one of
the locking rung and
the second side rail; and a user-operated actuator operably coupled to the
locking member to
alter the locking assembly between: (1) a locked state whereby the locking bar
is engaged by the
locking member so that the locking bar is prevented from sliding within the
track of the locking
rung; and (2) an unlocked state whereby the locking bar is released from the
locking member so
that the locking bar can slide freely within the track of the locking rung;
wherein when the
locking assembly is in the locked state the first ladder section is maintained
in a load bearing
ladder state in which the first and second side rails are spaced apart from
one another by a first
distance; and wherein when the locking assembly is in the unlocked state the
first ladder section
can be altered from the load bearing ladder state to a rail-to-rail collapsed
state in which the first
and second side rails are spaced apart from one another by a second distance
that is less than the
first distance.
[0008] In a yet further aspect, the invention can be a ladder comprising: a
first ladder section
comprising: a first side rail extending along a first axis; a second side rail
extending along a
second axis; a plurality of first rungs having a first end pivotably coupled
to the first side rail and
a second end pivotably coupled to the second side rail; a locking assembly
alterable between: (1)
a locked state in which the first ladder section is locked in a load bearing
ladder state; and (2) an
unlocked state in which the second side rail can be folded relative to the
first side rail to alter the
first ladder section between the load bearing ladder state and a rail-to-rail
collapsed state; a user-
operated actuator operably coupled to the locking assembly to alter the
locking assembly from
the locked state to the unlocked state; and the locking assembly comprising
indicia indicating
whether the locking assembly is in the locked state or the unlocked state.
[0009] In another aspect, the invention can be a collapsible ladder
comprising: two or more left
side elongate stringers hingedly affixed at a midpoint of the collapsible
ladder; two or more right
side elongate stringers hingedly affixed at a midpoint of the collapsible
ladder; a plurality of
rungs having left terminal ends and right terminal ends, the rungs hingedly
affixed at each
terminal end to a stringer; wherein the ladder is operable to collapse on a
longitudinal axis when
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the ladder is folded at a hinged midpoint; wherein the ladder is operable to
collapse on a lateral
axis when the left side stringers are moved longitudinally with respect to the
right side stringers.
[0010] In an even further aspect, the invention can be a ladder comprising: a
first ladder section
comprising: a first side rail extending along a first axis; a second side rail
extending along a
second axis; and a plurality of first rungs having a first end pivotably
coupled to the first side rail
and a second end pivotably coupled to the second side rail; a first locking
assembly alterable
between: (1) a locked state in which the first ladder section is locked in a
load bearing ladder
state; and (2) an unlocked state in which the second side rail can be folded
relative to the first
side rail to alter the first ladder section between the load bearing ladder
state and a rail-to-rail
collapsed state; a first user-operated actuator operably coupled to the first
locking assembly to
alter the locking assembly from the locked state to the unlocked state; a
second ladder section
comprising: a third side rail extending along a third axis; a fourth side rail
extending along a
fourth axis; and a plurality of second rungs extending between and coupled to
the third side rail
and the fourth side rail; the second ladder section alterable, by folding the
fourth side rail toward
the third side rail to cause pivoting about the first and second ends of the
plurality of second
rungs, between: (1) a load bearing ladder state; and (2) a rail-to-rail
collapsed state in which the
third and fourth side rails are adjacent one another; and a pair of hinges
pivotably coupling the
first and second ladder sections to one another, the pair of hinges adjustable
between and
lockable in a plurality of selectable angular configurations when each of the
first and second
ladder sections are in a load bearing state, the selectable angular
configurations comprising: a
straight ladder configuration in which the third axis of the third side rail
is substantially coaxial
with the first axis of the first side rail and the fourth axis of the fourth
side rail is substantially
coaxial with the second axis of the second side rail; a step ladder
configuration in which a first
acute angle is formed between the first axis of the first side rail and the
third axis of the third side
rail and a second acute angle is formed between the second axis of the second
side rail and the
fourth axis of the fourth side rail; and a folded configuration in which the
first and third side
rails extend adjacent one another and the second and fourth side rails extend
adjacent one
another.
[0011] In a still further aspect, the invention can be a ladder comprising: a
first ladder section
comprising: a first side rail extending along a first axis; a second side rail
extending along a
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second axis; a plurality of first rungs having first and second ends pivotably
coupled to the first
and second side rails by pivot connection assemblies that are nested between
front and rear walls
of the first and second side rails; and each of the pivot connection
assemblies comprising: an end
cap component comprising: a rung receiving tube having a sidewall having an
inner surface
defining a receiving cavity in which either the first or second end of one of
the first rungs is
positioned, the receiving cavity extending along a rung axis; and first and
second spacer tubes
extending from opposite sides of an outer surface of the rung receiving tube,
each of the first and
second spacer tubes extending along a pivot axis of either the first or second
end of one of the
first rungs; and a pivot pin extending along the pivot axis and having a first
end coupled to the
first side rail and a second end coupled to the second side rail, the pivot
pin extending through
the first and second spacer tube and the end of the first rung that is
positioned in the receiving
cavity.
[0012] Further areas of applicability of the present invention will become
apparent from the
detailed description provided hereinafter. It should be understood that the
detailed description
and specific examples, while indicating the preferred embodiment of the
invention, are intended
Brief Description of the Drawings
[0013] FIG. 1A illustrates a side perspective view of fully collapsible ladder
with hinged rungs
in accordance with the present invention;
[0014] FIG. 1B illustrates a forward side perspective view of fully
collapsible ladder with hinged
rungs in accordance with the present invention;
[0015] FIG. 1C illustrates a forward side perspective view of fully
collapsible ladder with hinged
rungs in accordance with the present invention;
[0016] FIG. 1D illustrates a forward side perspective view of fully
collapsible ladder with hinged
rungs in accordance with the present invention;
[0017] FIG. 2 illustrates a forward side perspective view of fully collapsible
ladder with hinged
rungs in accordance with the present invention;
[0018] FIG. 3 illustrates a forward side perspective view of fully collapsible
ladder with hinged
rungs in accordance with the present invention;
[0019] FIG. 4 illustrates a rearward, exploded perspective view of fully
collapsible ladder with
hinged rungs in accordance with the present invention;
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[0020] FIG. 5 illustrates a side perspective view of fully collapsible ladder
with hinged rungs in
accordance with the present invention;
[0021] FIG. 6 illustrates a side perspective view of fully collapsible ladder
and carrying tube
with hinged rungs in accordance with the present invention;
[0022] FIG. 7 illustrates a forward perspective view of fully collapsible
ladder with hinged rungs
in accordance with the present invention;
[0023] FIG. 8 illustrates a side perspective view of an interlocking hinge for
foldable ladders in
accordance with the prior art;
[0024] FIG. 9 is a perspective view of a ladder in accordance with an
embodiment of the present
invention, wherein the ladder is in an extended and non-collapsed
configuration;
[0025] FIG. 10 is a perspective view of the ladder of FIG. 9 in an extended
and collapsed
configuration;
[0026] FIG. 11 is a perspective view of the ladder of FIG. 9 in a step ladder
configuration;
[0027] FIG. 12 is a perspective view of the ladder of FIG. 9 in a folded and
non-collapsed
configuration;
[0028] FIG. 13 is a perspective view of the ladder of FIG. 9 in a folded and
collapsed
configuration;
[0029] FIG. 14 is a side view of the ladder of FIG. 13;
[0030] FIG. 15 is a cross-sectional view taken along line VII-VII of FIG. 14;
[0031] FIG. 16 is a cross-sectional view taken along line VIII-VIII of FIG.
15;
[0032] FIG. 17 is a close-up view of area IX of FIG. 15 illustrating an
actuator in a first state;
[0033] FIG. 18 is the close up view of FIG. 17 illustrating the actuator in a
second state;
[0034] FIG. 19 is a close-up view of area X of FIG. 15 illustrating a locking
member in a locked
state;
[0035] FIG. 20 is the close-up view of FIG. 18 illustrating the locking member
in the unlocked
state;
[0036] FIGS. 21-23 are close-up views of FIG. 20 sequentially illustrating the
process of altering
the ladder from the non-collapsed configuration of FIG. 12 to the collapsed
configuration of FIG.
13;
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[0037] FIG. 24 is another perspective view of the ladder of FIG. 9 in the
folded and non-
collapsed configuration;
[0038] FIG. 25 is a close-up view of area XVII of FIG. 24 with the locking
member in the
locked state;
[0039] FIG. 26 is a close-up view of area XVII of FIG. 24 with the locking
member in the
unlocked state;
[0040] FIG. 27 is a perspective view of a ladder in a step ladder
configuration in accordance
with an alternative embodiment of the present invention;
[0041] FIG. 28 is a close-up view of the locking assembly as the ladder begins
to be altered from
the rail-to-rail collapsed state to the load bearing ladder state;
[0042] FIG. 29 is a close-up view of the locking assembly as the locking
component of the
locking bar contacts the cam surface of the locking member to impart an
opening force on the
locking member that causes the locking member to pivot;
[0043] FIG. 30 is close-up view of the locking assembly after the locking
component has ridden
over the cam surface and the locking member is biased back into the locking
state; and
[0044] FIG. 31 is a cross-section taken along view XXXI-XXXI of FIG. 12
showing the details
of how the ends of the rungs are pivotably coupled to the first and second
side rails.
Detailed Description of the Invention
[0045] The following description of the preferred embodiment(s) is merely
exemplary in nature
and is in no way intended to limit the invention, its application, or uses.
[0046] The description of illustrative embodiments according to principles of
the present
invention is intended to be read in connection with the accompanying drawings,
which are to be
considered part of the entire written description. In the description of
embodiments of the
invention disclosed herein, any reference to direction or orientation is
merely intended for
convenience of description and is not intended in any way to limit the scope
of the present
invention. Relative terms such as "lower," "upper," "horizontal," "vertical,"
"above," "below,"
"up," "down," "top" and "bottom" as well as derivatives thereof (e.g.,
"horizontally,"
"downwardly," "upwardly," etc.) should be construed to refer to the
orientation as then described
or as shown in the drawing under discussion. These relative terms are for
convenience of
description only and do not require that the apparatus be constructed or
operated in a particular
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orientation unless explicitly indicated as such.
Terms such as "attached," "affixed,"
"connected," "coupled," "interconnected," and similar refer to a relationship
wherein structures
are secured or attached to one another either directly or indirectly through
intervening structures,
as well as both movable or rigid attachments or relationships, unless
expressly described
otherwise. Moreover, the features and benefits of the invention are
illustrated by reference to the
exemplified embodiments. Accordingly, the invention expressly should not be
limited to such
exemplary embodiments illustrating some possible non-limiting combination of
features that
may exist alone or in other combinations of features; the scope of the
invention being defined by
the claims appended hereto.
[0047] Figure lA ¨ 1B illustrate a forward side perspective view of fully
collapsible ladder with
hinged rungs 1100 in accordance with the present invention.
[0048] A plurality of rung members 11104a-b are hingedly affixed to two or
more elongate
stringers 1102a-b. Each rung 1104 comprises two terminal ends 1122a-b, with
each terminal end
1122 hingedly affixed to a stringer 1102.
[0049] Each of the rung members 1104 comprises an elongate shaft, tube, beam,
rod, or extruded
polymeric or aluminum step or rung portion having a first end terminal end
1122a and second
terminal end 1122b.
[0050] The stringers 1102 may also be provided with apertures 1142 which serve
as hand holds
for porting the ladder 1100.
[0051] The ladder 1100 folds at hinges 1800 affixed between adjacent stringers
1102. The hinge
1800 is known to those of skill in the art, and further described below in
relation to Figure 8.
[0052] Figure lA shown the ladder 1100 in a fully collapsed configuration on
both axes while
Figure 1B shows the ladder 1100 is semi-collapsed configuration on a single
axis. When the
ladder 1100 is in either a fully collapsed or semi-collapsed configuration,
the ladder 1100 is
operable to collapse on its widthwise axis by moving the stringers 1102 along
one side of the
rungs 1104 along the longitudinal axis against the position of the stringers
1102 on an opposing
side of the ladder 1100. The ladder 1100 is operable to collapse on both
lengthwise and
widthwise axes in a semi-collapsed or fully extended position.
[0053] Figure 1C illustrates a forward side perspective view of fully
collapsible ladder 1140 with
hinged rungs in accordance with the present invention.
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[0054] Shown in an open semi-collapsed position, the ladder 1140 may also be
folded open at
the hinges 1800 to configure as a fully-extended position depicted in Figure
1D.
[0055] The ladder 1140 is provided with a latching mechanism 1144. The
latching
mechanism 1144 may include a simple hinge as known to those of skill in the
art or a more
complex hinge 1800 as further described below.
[0056] Figure 1D illustrates a forward side perspective view of fully
collapsible ladder with
hinged rungs in accordance with the present invention.
[0057] In its fully extended position shown, the ladder 1160 is operable to
collapse on its
widthwise, or lateral, axis by moving the stringer 1102 in vertically opposed
directions.
[0058] Figure 2 illustrates a forward side perspective view of fully
collapsible ladder 1200 with
hinged rungs in accordance with the present invention.
[0059] The rungs 1104 may be formed with ridges, molded or otherwise formed
thereon, to
increase track and stability of a user positioned on the rungs 1104. These
ridges 1702 act to
provide a relatively non-slip surface on the steps. Other non-slip surfaces
may be provided
instead, as would be evident to a person skilled in the art.
[0060] Figure 3 illustrates a forward side perspective view of fully
collapsible ladder 1300 with
hinged rungs in accordance with the present invention.
[0061] The rungs 1104 operate to pivot about attachment point with the
stringers 1102.
[0062] Figure 4 illustrates a rearward, exploded perspective view of fully
collapsible ladder 1400
with hinged rungs in accordance with the present invention.
[0063] In various embodiments, the ladder 1400 comprises a diagonal brace 1402
which
positions beneath each rung 1104. The diagonal brace 1402 is hingedly affixed
at first terminal
end 404 to a stringer 1102 as shown. At a second terminal end 1406, the
diagonal brace 1402
affixes to one of a rung 1104 and/or a pully or track within which the second
terminal end 1406
travels. The second terminal end 1406 may affix to mounting bracket 1408 which
travels within
a traveling mechanism such as the pully 1410 shown.
[0064] The diagonal brace 1402 is adapted to restrict motion of the rung 1104
to which the
diagonal brace 1402 is connected from moving more than 90 degrees. In the
shown
embodiment, the rung 1104 is restricted from axially rotating about its left
terminal end in a
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clockwise direction when the rung 1104 is in perpendicular orientation to the
stringer 1102 from
a forward perspective.
[0065] The ladder 1400 may comprise a plurality of polymeric feet 1412.
[0066] Figure 5 illustrates a side perspective view of fully collapsible
ladder 1500 with hinged
rungs in accordance with the present invention. The ladder 1500 is shown in a
semi-collapsed
configuration.
[0067] Figure 6 illustrates a side perspective view of fully collapsible
ladder and carrying tube
600 with hinged rungs in accordance with the present invention.
[0068] The fully collapsed ladder 1100 may insert into a tube 1602 which
allows the ladder 1100
to be ported without unfolding during transport. The tube 1602 may cylindrical
and formed from
polymeric or metal alloy.
[0069] If needed, a user can stack multiple fully collapsed ladders 1100 one
upon one another.
[0070] Figure 7 illustrates a forward perspective view of fully collapsible
ladder 1700 with
hinged rungs in accordance with the present invention.
[0071] In various embodiments, the rungs 1104 are hingedly affixed to pivot
less than 90
degrees off a perpendicular orientation to the stringer 1102, with each rung
1102 pivoting
forward on a vertical (or longitudinal) axis at one terminal end and rearward
on the vertical axis
at the opposing vertical end.
[0072] Figure 8 illustrates a side perspective view of an interlocking hinge
1800 for foldable
ladders in accordance with the prior art.
[0073] A hinge 1800 for foldable ladders known in the prior art comprises a
first joint member
integrally formed with main discs, a second joint member integrally formed
with a sub disc, a
locking device having a button, a connecting pin, a coil spring, a rectangular
locking block and a
press locking control device for controlling to latch or unlatch the locking
device. The first and
second joint members are combined together through a common axis of a center
shaft enabling
them to rotate. The sub disc of the second joint member is inserted between a
pair of parallel
spaced main discs of the first joint member. The main discs of the first joint
member have slot
openings for inserting the locking device. The first protruded arcuate stopper
is disposed at the
inner surface of the main disc. The second protruded arcuate stopper is formed
at the rear surface
of the sub disc of the second joint member for matching with the first
protruded arcuate stopper
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of main disc. A plurality of detents is formed around periphery of the sub
disc. At one side of
slot opening of the main disc, a press locking control device is installed for
elastically actuating
the device.
[0074] The hinge 1800 may be integrated into a ladder 1100 as shown, between
two stringer
1102. In various configurations, the hinge 1800 positions at a midway point on
the ladder 1100
between two stringers of identical length.
[0075] Referring to FIG. 9, a ladder 100 is illustrated in accordance with an
embodiment of the
present invention. The ladder 100 generally comprises a first ladder section
300 and a second
ladder section 400. A pair of locking hinges, comprising a first locking hinge
115 and a second
locking hinge 125, pivotably couple the first and second ladder sections 300,
400 to one another.
As will be discussed in greater detail below, the pair of hinges 115, 125 are
adjustable between
and lockable in a plurality of selectable angular configurations when each of
the first and second
ladder sections 300, 400 are in a load bearing state. The selectable angular
configurations
comprising a straight ladder configuration (shown in FIG. 9), a step ladder
configuration (shown
in FIG. 11), and a folded configuration (shown in FIG. 12). In certain
embodiments, the ladder
100 may be designed such that the selectable angular configurations only
include the step ladder
configuration (shown in FIG. 11) and the folded configuration (shown in FIG.
12). In other
embodiments, the ladder 100 may only comprise the first ladder section 300 in
which the second
ladder section 400 and pair of hinges 115, 125 are omitted.
[0076] The first ladder section 300 generally comprises a first side rail 110
extending from a
bottom end 111 to a top end 112 along a first axis A-A and a second side rail
120 extending from
a bottom end 121 to a second end 122 along a second axis B-B. The first side
rail 110 comprises
an inner surface 116 and an outer surface 117 and the second side rail 120
comprises an inner
surface 126 (FIG. 15) and an outer surface 127.
[0077] The first ladder section 300 also comprises a plurality of first rungs
(which comprise first
non-locking rungs 130 and first locking rung 140) extending between the first
and second side
rails 110, 120. Each of the plurality of first non-locking rungs 130 comprises
a first end 131 that
is pivotably coupled to the first side rail 110 along or adjacent to the inner
surface 116 of the first
side rail 110 and a second end 132 (shown in FIG. 15) that is pivotably
coupled to the second
side rail 120 along or adjacent to the inner surface 126 of the second side
rail 120. The first ends
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131 of the non-locking rungs 130 comprise an aperture through which a pin/rod
that is connected
to the front and rear sidewalls 102, 103 of the first side rail 110 extends to
permit the pivotability
of the first non-locking rungs 130 relative to the first side rail 110.
Similarly, the second ends
132 of the first non-locking rungs 130 comprise an aperture through which a
pin/rod that is
connected to the front and rear sidewalls 105, 106 (not visible) of the second
side rail 120
extends to permit the pivotability of the first non-locking rungs 130 relative
to the second side
rail 120. The first non-locking rungs 130 are all freely pivotable relative to
the first and second
side rails 110, 120 to facilitate altering the first ladder section 300
between a load bearing ladder
state (shown in FIGS. 9, 11 and 12) and a rail-to-rail collapsed state (shown
in FIGS. 10 and 13),
as will be describe din greater detail below.
[0078] More specifically, and now referring to FIGS. 12 and 31 concurrently,
each of the first
and second ends 131, 132 of the first rungs 130 are pivotably coupled to the
first and second side
rails 110, 120 by a pivot connection assembly generally comprising an end cap
component 750.
While the pivotable connection will be described below with respect to the
first end 131 of one
of the first rungs 130 being pivotably coupled to the first side rail 110, it
is to be understood that
the second ends 132 of the first rungs 130 are pivotably coupled to the second
side rail 120 in an
identical manner. Moreover, the second rungs 430 of the second ladder section
400 are also
pivotable coupled to the third and fourth rails 410, 420 in an identical
manner.
[0079] As can be seen in FIG. 31, the end cap component 750 is nested between
the portions of
the front and rear walls 102, 103 of the first and second side rails 110 that
extend form the inner
wall 212. The end cap component 750 comprises a rung receiving tube 751 having
a sidewall
having an inner surface 752 defining a receiving cavity 753 in which the first
end 131 of the first
rung 130 is positioned. The receiving cavity 753 extends along a rung axis R-
R. The end cap
component 750 further comprises first and second spacer tubes 755, 756
extending from opposite
sides of an outer surface 752 of the rung receiving tube 751. Each of the
first and second spacer
tubes 755, 756 extend along a pivot axis P-P upon which the first end 131 of
the first rung 130
pivots when the first ladder section 300 is altered between the load bearing
ladder state and the
rail-to-rail collapsed state.
[0080] A pivot pin 760 is provided that extends along the pivot axis P-P and
has a first end
coupled to the front wall 102 of the first side rail 110 and a second end
coupled to the rear wall
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103 of the first side rail 110. As can be seen, the pivot pin 760 extending
through the first and
second spacer tubes 755, 756, through the first end 131 of the first rung 130
that is positioned in
the receiving cavity 753, and through apertures in the front and rear walls
102, 103 of the first
side rail 110. The spacer tubes 755, 756 have an outer diameter that is larger
than the apertures
in the in the front and rear walls 102, 103 of the first side rail 110 through
which the pin 760
extends. Thus, the spacer tubes 755, 756 maintain the first rung 130 in a
properly spaced
relationship from the front and rear walls 102, 103 of the first side rail
110. Finally, the rung
receiving tube 751 has a closed end wall that prevents sliding of the first
rung 130 within the end
cap component 750.
[0081] Referring back to FIG. 9, similar to the first ladder section 300, the
second ladder section
400 generally comprises a third side rail 410 extending from a bottom end 411
to a top end 412
along a third axis F-F and a fourth side rail 420 extending from a bottom end
421 to a top end
422 along a fourth axis G-G. As shown in FIG. 9 in which the ladder 100 is in
the straight ladder
configuration, the third axis F-F of the third side rail 410 is substantially
coaxial with the first
axis A-A of the first side rail 110 and the fourth axis G-G of the fourth side
rail 420 is
substantially coaxial with the second axis B-B of the second side rail 120.
When in the step
ladder configuration, as shown in FIG. 11, a first acute angle 01 is formed
between the first axis
A-A of the first side rail 110 and the third axis F-F of the third side rail
410 and a second acute
angle 02 is formed between the second axis B-B of the second side rail 120 and
the fourth axis
G-G of the fourth side rail 420. When in the folded configuration, as shown in
FIG. 12, the first
and third side rails 110, 410 extend adjacent one another and the second and
fourth side rails
120, 420 extend adjacent one another. Moreover, in certain embodiments, when
in the folded
state, the first and third axes A-A, F-F are substantially parallel to one
another and the second
and fourth axes B-B, G-G are substantially parallel to one another shown in
FIG., 12).
[0082] The third side rail 410 comprises an inner surface 413 and an outer
surface 414 and the
fourth side rail 420 comprises an inner surface (not visible) and an outer
surface 424. The
second ladder section 400 also comprises a plurality of cross-members, which
in the exemplified
embodiment is a plurality of second rungs 430, which are non-locking rungs (as
described below,
in other embodiments, such as the one shown in FIGS. 27A-B the plurality of
second rungs 430
may include a locking rung 435). In other embodiments where it is not desired
that the second
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ladder section be a load bearing ladder section, the cross-members may take
the form of struts
that are either collapsible and/or pivotably coupled to the third and fourth
side rails 410, 420.
[0083] The plurality of second rungs 430 are pivotably coupled to the third
and fourth side rails
410, 420 in the same manner in which the first non-locking rungs 130 are
coupled to the first and
second side rails 110, 120. Thus, while not called out in detail in the FIGS.,
each of the plurality
of second rungs 430 comprises a first end that is pivotably coupled to the
third side rail 410
along or adjacent to the inner surface 413 of the third side rail 410 and a
second end that is
pivotably coupled to the fourth side rail 420 along or adjacent to the inner
surface of the second
side rail 420. Thus, in the exemplified embodiment, the second rungs 430 are
all freely pivotable
relative to the third and fourth side rails 410, 420 to facilitate altering
the second ladder section
400 between a load bearing ladder state (shown in FIGS. 9, 11 and 12) and a
rail-to-rail
collapsed state (shown in FIGS. 10 and 13), as will be describe din greater
detail below.
[0084] As mentioned above, the first and second locking hinges 115, 125 are
adjustable between
and lockable in a plurality of selectable angular configurations. When rotated
into one of the
selectable angular configurations (e.g., the straight ladder configuration,
the step ladder
configuration, and the folded configuration), the first and second locking
hinges 115, 125 will
automatically assume a locked state as the result of resilient elements, such
as coil springs,
biasing the first and second locking hinges 115, 125into a mechanical
interlock. The first and
second locking hinges 115, 125 will remain in the locked state until a user
applies force to a
hinge actuator that will overcome the bias of the resilient elements and
release the mechanical
interlock. Once the mechanical interlock is released, the first and second
ladder sections 300,
400 can be rotated relative to one another about a rotational axis C-C that is
transverse to the
first, second, third, and fourth axes A-A, B-B, F-F, and G-G. As such, the
ladder 100 can be
altered between and locked in the selectable angular configurations.
[0085] The first and second locking hinges 115, 125 can be the hinge shown and
described
above with respect to FIG. 8. Additionally, examples of suitable hinges for
the first and second
locking hinges 115, 125 are shown described in U.S. Patent No. 7,364,017, U.S.
Patent No.
7,264,082, U.S. Patent No. 6,220,389, U.S. Patent No. 7,047,597, U.S. Patent
No. 6,886,117, and
U.S. Patent No. 4,182,431, the entireties of which are incorporated herein by
reference.
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[0086] Referring now to FIGS. 9, 15, and 31 concurrently, the first side rail
110 comprises a first
enclosed channel 101 and a first open channel 201. The first side rail 110
comprises a first outer
wall 211 comprising the outer surface 117, a first inner wall 212 comprising
the inner surface
126, the first front wall 102, and the first rear wall 103. The first enclosed
channel 101
comprises a closed transverse cross-sectional profile formed by the first
outer wall 211, the first
inner wall 212, the first front wall 102, and the first rear wall 103. The
first open channel 201
comprises a U-shaped open transverse cross-sectional profile formed by the
first inner wall 212,
a portion of the first front wall 102 that extends inward beyond the first
inner wall 212, and a
portion of the first rear wall 103 that extends inward beyond the first inner
wall 212.
[0087] Similarly, the second side rail 120 comprises a second enclosed channel
104 and a second
open channel 202. The second side rail 120 comprises a first outer wall 221
comprising the outer
surface 127, a first inner wall 222 comprising the inner surface 126, the
second front wall 105,
and the second rear wall (not visible). The second enclosed channel 104
comprises a closed
transverse cross-sectional profile formed by the second outer wall 221, the
second inner wall
222, the second front wall 105, and the second rear wall. The second open
channel 202
comprises a U-shaped open transverse cross-sectional profile formed by the
second inner wall
222, a portion of the second front wall 105 that extends inward beyond the
second inner wall
222, and a portion of the second rear wall that extends inward beyond the
second inner wall 222.
[0088] As can be understood from the above discussion, the first and second
side-rails 110, 120
have the same construction and the same transverse cross-sectional profile
and, in some
embodiments, are sections of the same extruded rail. Moreover, while not
discussed herein in
detail to avoid redundancy, the third and fourth side rails 410, 410 also have
the same
construction and same transverse cross-sectional profile as the first and
second side rails 110,
120 and, thus, also comprise an open channel and a closed channel as described
above.
[0089] Referring now to FIGS. 12 and 13 concurrently, when in the folded
configuration, both
the first and second ladder sections 300, 400 are alterable between a load
bearing ladder state
(FIG. 12) and a rail-to-rail collapsed state (FIG. 13). The first ladder
section 300 is altered from
the load bearing ladder state to the rail-to-rail collapsed state by folding
the second side rail 120
relative to the first side rail 110 to cause pivoting about the first and
second ends 131, 132 of the
plurality of first rungs 130, 140. When the first ladder section 300 is in the
load bearing ladder
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state, the first and second side rails 110, 120 are substantially parallel to
and spaced from one
another a first distance and the plurality of first rungs 130, 140 are
substantially perpendicular to
the first and second side rails 110, 120 (and, thus, the first and second axes
A-A, B-B). When
the first ladder section 300 is in in the rail-to-rail collapsed state, the
first and second side rails
110, 120 are substantially parallel to and spaced from one another a second
distance and the
plurality of first rungs 130, 140 are inclined relative to the first and
second side rails 110, 120
(and, thus, the first and second axes A-A, B-B). The first distance is greater
than the second
distance.
[0090] Similarly, the second ladder section 400 is also altered from the load
bearing ladder state
to the rail-to-rail collapsed state by folding the second side rail 420
relative to the first side rail
410 to cause pivoting about the first end 431 and the second ends (not
visible) of the plurality of
second rungs 430. When the second ladder section 400 is in the load bearing
ladder state, the
third and fourth side rails 410, 420 are substantially parallel to and spaced
from one another a
first distance and the plurality of second rungs 430 are substantially
perpendicular to the third
and fourth side rails 410, 420 (and, thus, the third and fourth axes F-F, G-
G). When the second
ladder section 400 is in in the rail-to-rail collapsed state, the third and
fourth side rails 410, 420
are substantially parallel to and spaced from one another a second distance
and the plurality of
second rungs 430 are inclined relative to the third and fourth side rails 410,
420 (and, thus, the
third and fourth axes F-F, G-G). The first distance is greater than the second
distance.
[0091] Because the first and second ladder sections 300, 400 are coupled
together via the pair of
hinges 115, 125 (and specifically the second side rail 120 is coupled to the
fourth side rail 420
side rail 410 by the hinge 125, the second and fourth side rails 120, 420 move
as unit. Thus, the
first and second ladder sections 300, 400 are contemporaneously altered
between their load
bearing ladder state to their rail-to-rail collapsed in a concerted manner.
Additionally, during the
transition from the load bearing ladder state to the rail-to-rail collapsed of
the first ladder section
300, the first side rail 110, the second side rail 120, and the plurality of
first rungs 130, 140
maintain a first parallelogram linkage. Similarly, during the transition from
the load bearing
ladder state to the rail-to-rail collapsed of the second ladder section 400,
the third side rail 410,
the fourth side rail 420, and the plurality of second rungs 430 maintain a
second parallelogram
linkage.
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[0092] As will be described in greater detail below, the first ladder section
100 further comprises
a user-operated actuator 160 and a locking assembly 190. The user-operated
actuator 160 is
operably coupled to the locking assembly 190 to alter the locking assembly 190
from a locked
state to an unlocked state upon an actuation force being applied to the user-
operated actuator 160
in an upward axial direction (moving from the bottom end 121 of the second
side rail 120 toward
the top end 122 of the second side rail 120). When the locking assembly 190 is
in the locked
state, the first ladder section 300 (and thus the second ladder section 400)
is locked in its load
bearing ladder state and can not be altered into its rail-to-rail collapsed
configuration. When the
locking assembly 190 is in the unlocked state, the second side rail 120 can be
folded relative to
the first side rail 110 to alter the first ladder section 300 between its load
bearing ladder state and
its rail-to-rail collapsed state (as can the second ladder section 400).
[0093] When the first and second ladder sections 300, 400 are in the load
bearing ladder states
(shown in FIGS. 9, 11, and 12), each of the first and second rungs 130, 140,
430 are configured
to support the weight of a user of the ladder 100. Furthermore, each of the
first and second rungs
130, 140, 430 may have a textured upper surface to prevent slippage by a user
during use.
[0094] Referring to FIGS. 12-14 concurrently, the first ladder section 300
also comprises a first
handle 118 on the first side rail 110 and a second handle 119 on the second
side rail 120. The
first and second handles 118, 119 are positions on the first and second side
rails 110, 120
respectively so that when the first ladder section 300 is in the load bearing
ladder state, the first
and second handles 118, 119 are offset from one another in an axial direction
(as shown in FIGS.
12 and 14). As can be seen, the first handle 118 is located a first distance
from the bottom end
111 of the first side rail 110 and the second handle 119 is located a second
distance from a
bottom end 121 of the second side rail 120, the first distance being greater
than the second
distance.
[0095] When the first ladder section 300 is altered into the rail-to-rail
collapsed state, the first
and second handles 118, 119 are at least partially aligned with one another in
the axial direction.
Most preferably, as shown in FIG. 13, when the first ladder section 300 is
altered into the rail-to-
rail collapsed state, the first and second handles 118, 119 are in complete
alignment with one
another in the axial direction. Having the first and second handles 118, 119
positioned so as to
be at least partially aligned as set forth above, a user can grasp and
transport the ladder 100
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(when both the first and second ladder sections 300, 400 are in the rail-to-
rail configuration) with
a single hand.
[0096] Each of the first and second side rails 110, 120 comprise a front
surface 240A, 240B
having an inner edge 241A, 241B and an outer edge 242A, 242B respectively. The
first handle
118 is positioned on the front face of the first side rail adjacent the inner
edge 241A of the front
surface 240A of the first side rail 110. The second handle 119 is positioned
on the front surface
240B of the second side rail 120 adjacent the inner edge 241B of the front
surface face 240B of
the second side rail 120. As a result of this placement, the user's ability to
carry the ladder 100
in the rail-to-rail collapsed state with one hand is further facilitated.
Moreover, this positioning
of the first and second handles 118, 119 maintains the first and second ladder
sections 300, 400
in the rail-to-rail collapsed state when the first and second handles are
gripped.
[0097] In the exemplified embodiment, each of the first and second handles
118, 119 comprises
a strap component. In other embodiments, the handles 118, 119 may be in the
form of flexible or
rigid structure, protuberances, cutouts, or other gripping structures.
[0098] Referring to FIGS. 9 and 15-16 concurrently, the first ladder section
300 further
comprises at least one locking rung 140 having a first end 141 pivotably
coupled to the first side
rail 110 and a second end 142 (FIG. 15) connected to the second side rail 120.
In some
embodiments, the second end 142 may be pivotably coupled to the second side
rail 120, although
this may not be required in all embodiments. The coupling of the locking rung
140 to the first
and second side rails 110, 120 may be achieved in the same manner as the
coupling of the non-
locking rungs 130 to the first and second side rails 110, 120 described above
(using an
aperture/pin structure). In the exemplified embodiment, there is only one of
the locking rungs
140, but the invention is not to be so limited in all embodiments and the
ladder 100 could include
more than one of the locking rungs 140 on the first and/or second ladder
sections 300, 400 as
desired. In the exemplified embodiment, the locking rung 140 is the lowermost
rung of the first
ladder section 300, although the invention is not to be so limited in all
embodiments and the
locking rung 140 could be located at other positions along the ladder 100. The
locking rung 140
is also configured to support the weight of a user when the first ladder
section 300 is in the load
bearing ladder state.
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[0099] The locking first rung 140 has a different cross-sectional shape than
the non-locking first
rungs 130. Specifically, the non-locking rung 140 comprises an upper surface
143, a lower
surface 144, and a track 145 formed into the lower surface 144 having an
opening in the lower
surface 144. The track 145 is essentially a channel formed into the non-
locking rung 140. The
track 145 is configured to slidably receive a portion of a locking bar 150 so
that the locking bar
150 can slide within the track 145 relative to the locking rung 140 when the
first ladder section
300 is altered between load bearing ladder state and the rail-to-rail
collapsed states.
[00100] Referring now to FIGS. 9 and 15 concurrently, the first ladder
section 300
comprises a locking assembly 190 that generally comprises the locking bar 150,
a locking
member 170, and a resilient element 275 (FIG. 19). The resilient element 275,
which is
exemplified as a torsion spring, is operably coupled to the locking member 170
as will be
described in greater detail below with respect to the functioning of the
locking assembly 190. A
user-operated actuator 160 is operably coupled to locking assembly 190 to be
capable of altering
the locking assembly 190 from a locked state (see FIG. 19) to an unlocked
state (see FIG. 20)
upon an actuation force being applied to the user-operated actuator 160. In
the exemplified
embodiment, the actuator 160 is operably coupled to the locking assembly 190
by a linkage 180.
The linkage 180 is a rigid rod in the exemplified but embodiment but can take
on may forms,
such as a flexible cable, a bar, or coupler. In the exemplified embodiment,
the linkage 180 is
located within the second enclosed channel 104 of the second side rail 120 so
that the cable 180
is not exposed to a user but rather is positioned internally and out of sight
during normal use and
operation of the ladder 110.
[00101] Referring now to FIGS. 15 and 17-20, a process of altering the
locking assembly
190, using the actuator 160, from a locked state (in which the first ladder
section 300 is locked in
the load bearing ladder state) and an unlocked state (in which the first
ladder section 300 can be
altered from the load bearing ladder state to the rail-to-rail collapsed
state) will be described.
[00102] Starting with FIGS. 17 and 19, the first ladder section 300 is in
the load bearing
ladder state (such as that which is shown in FIG. 12). When in this state, the
locking assembly
190 is in a locked state (shown in FIG. 19) and the actuator 160 is in a first
state (shown in FIG.
17). The actuator 160 comprises slide trigger 161 and a resilient element 162,
which is in the
form of a coil spring 162. The slide trigger 161 is nested within a depression
165 in the outer
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surface 127 of the second side rail 120. As can be seen, the slide trigger 161
is coupled to the
linkage 180 and both the slide trigger 161 and the linkage 180 are disposed
within the second
enclosed channel 104.
[00103] The resilient element 162 is arranged such that the actuator 160
is biased into the
first state. When the actuator 160 is in the first state, the locking member
170 is also in the
locked state, as will be described below. In the exemplified embodiment, the
resilient element
162 is a compression coil spring. However, the invention is not to be so
limited in all
embodiments and the resilient element 162 could be a flexible member formed
from rubber or
the like, or it could be a different type of spring.
[00104] The trigger 161 is located within a housing 163 of the actuator
160 and can be
moved upwardly for actuation as shown by the arrow in FIG. 17. The distance of
movement of
the trigger 161 for actuation may be relatively small, such as 0.1 to 3
inches, or more specifically
0.1 to 2 inches, or more specifically 0.1 to 1 inch.
[00105] The locking member 170 is pivotably mounted to the second side rail
120. The locking
member 170 (and the locking bar 150) are illustrated in the position that
corresponds to the
actuator 160 being in the first state. As noted above, the linkage 180 is
operably coupled to the
locking member 170 at one end and the slide trigger 161 of the actuator 160 at
the other end 182.
Thus, if the linkage 180 moves upwardly in the direction of the arrow due to
actuation of the
actuator 160 from the first state to the second state, the locking member 170
will pivot about a
pivot axis D-D as shown by the arcuate arrow.
[00106] The locking member 170 comprises a first portion 176 located within
the second
enclosed channel 104 and a second portion 177 protruding from the second inner
wall 222. As
can be seen, the locking member 170 extends through an opening 175 in the
second inner wall
222of the second rail 120 so that the second portion 177 is located within the
second open
channel 202 of the second side rail 120. The linkage 180 is coupled to the
first portion 175 of
the locking member 170. The second portion 177 of the locking member 170
comprises an
engagement feature 172, in the form of socket, that engages a locking
component 155 of the
locking bar 150. As a result of the engagement between the engagement feature
172 and the
locking component 155 of the locking bar 150, the locking bar 150 is locked in
place and can not
slide relative to the locking rung 140. If not for the locking component 155
being engaged by
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the engagement feature 172, the locking bar 150 would be freely slidable
relative to the locking
rung 140.
[00107] The resilient element 275, which is torsion spring that engages the
locking member 170
and an edge of the locking rung 140, biases the locking member 170 into the
locked state shown
in FIG. 19. The locking member 170 comprises an elongated arcuate slot 171 and
a second end
181 of the cable 180 is coupled to the locking member 170 within the slot 171.
[00108] The actuator 160 is operably coupled to the linkage 180 so that upward
axial movement
of the trigger 161 (away from the bottom end 121 of the second side rail 120)
also results in
upward axial movement of the linkage 180.
[00109] Referring now to FIGS. 18 and 20, the actuator 160 is illustrated as
being moved to the
second state and the locking member 170 is illustraetd as having been pivoted
to the unlocked
state. To alter the actuator 160 from the first state to the second state, a
user engages the trigger
161 and pulls upwardly on the trigger 161, thereby producing an actuation
force on the trigger
161 in an axial upward direction towards the first and second locking hinges
115, 125 (i.e., away
from the first end 121 of the second side rail 120). In doing this, the
resilient element 162
compresses and the trigger 161 moves axially upward within the housing 163.
Because the
trigger 161 is operably coupled to the linkage 180, the linkage 180 also moves
axially upward,
thereby overcoming the bias of the resilient element 275 and causing the
locking member 170 to
pivot about axis D-D from the locked state (FIG. 19) to the unlocked state
(FIG.20). During this
motion, the second end 181 of the linkage 80 engages an end wall 178 of the
elongated slot 171,
thereby causing the locking member 170 to pivot about axis D-D as the actuator
160 is moved
form the first state to the second state.
[00110] In order to alter the locking assembly 190 from the locked state (FIG.
19) to the
unlocked state (FIG. 20) the force applied to the user-operated actuator 160
in the upward axial
direction must overcome the biasing force of both of the resilient elements
162, 275. Upon a
user releasing the trigger 161, the trigger 161 will automatically alter back
from the second state
of FIG. 18 to the first state of FIG. 17. This is because the resilient
element 162 and the resilient
element 275 are biased to return to their normal state.
[00111] Referring now to FIGS. 21-23, once the locking assembly 190 (via
rotation of the
locking member 170) achieves the unlocked state, continued application of the
force to the first
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user-operated actuator 160 in the upward axial direction causes the second
side rail 120 to lift
relative to and fold toward the first side rail 110. As a result, the first
ladder section 300 can be
altered from the load bearing ladder state (FIG. 12) to the rail-to-rail
collapsed state (FIG.13).
As mentioned earlier, due their coupling, the second ladder section 400 will
also be altered from
the load bearing ladder state (FIG. 12) to the rail-to-rail collapsed state
(FIG.13).
[00112] As the user raises the second side rail 120 relative to the first side
rail 110 (and folds
the second side rail 120 towards the first side rail 110), the locking bar 150
will being to slide
within the track 145 of the locking bar 140 in a direction away from the
locking member 170.
During this movement, the second side rail 120 moves towards the first side
rail 110 by pivoting
each of the non-locking rails 130 and the locking rail 140 about their
respective pivot axes. As
shown in FIG. 21 as the second side rail 120 is being lifted relative to the
first side rail 110, the
second end 152 of the locking bar 150 slides within the track 145 of the
locking rung 140 in a
direction away from the locking member 170 and also away from the second side
rail 120 and
towards the first side rail 110. Once the locking component 155 of the locking
bar 150 has
moved out of alignment with the engagement feature 172, the user can release
the actuator 160.
Because the locking component 155 of the locking bar 150 has moved away from
the
engagement feature 172, releasing the actuator 160 will not lock the locking
assembly 190.
FIGS. 22 and 23 illustrate the continued sliding movement of the second end
152 of the locking
bar 150 within the track 145 of the locking rung 140 as the second side rail
120 continues to be
moved towards the first side rail 110. The second end 152 of the locking bar
150 moves further
and further away from the locking member 170 and the second rail 120 to
facilitate the collapse
of the ladder 110. Because each of the non-locking rungs 130 are freely
pivotably coupled to the
first and second side rails 110, 120, once the locking assembly 190 is altered
into the unlocked
state there is nothing to prevent a user from collapsing the ladder 100 as
described herein.
[00113] It should be appreciated that the ladder 100 will not alter into its
collapsed state
automatically. Rather, user action is needed to move the second side rail 120
towards the first
side rail 110 as described herein. This is because the locking bar 150 has a
moment of inertia
that keeps the locking bar 150 in the locked position (the position at which
it can be coupled to
the locking member 170). A user must take action to move the locking bar 150
away from the
locked position, such action being lifting/pivoting the second side rail 120
towards the first side
23
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rail. As seen in the figures and described herein, the same upward actuation
motion that takes
place to actuate the actuator 160 is also used to facilitate the rail-to-rail
collapsing of the ladder
100.
[00114] Referring now to FIGS. 28-30, the process by which the locking
assembly 190 assumed
the locked state as the first ladder section 300 is altered from the rail-to-
rail collapsed state to the
load bearing ladder state will be described. Referring to FIG. 28, as the
first ladder section 300
is altered from the rail-to-rail collapsed state to the load bearing ladder
state, the second side rail
120 is lowered and folded away from the first side rail 110. As a result, the
second end 152 of
the locking bar 150 begins to slide within the track 145 of the locking rung
140 toward the
second side rail 120 as indicated by the motion arrow. Referring to FIG. 29,
this sliding
continues unobstructed until the locking component 155 of the locking bar 150
contacts a cam
surface 179 of the locking member 170. As the lowering and folding away of the
second side
rail 120 relative to the first side rail 110 continues, the locking component
155 exerts an opening
force to the cam surface 179 of the locking member 170, thereby overcoming the
bias of the
resilient element 275 and causing the locking member 170 to pivot about the
axis D-D.
However, because the second end 181 of the linkage 180 can slide freely within
the arcuate slot
171, the locking member 170 pivots from the locked state toward the unlocked
state while the
actuator 160 remains in the first state. In other words, the opening force
must only overcome the
biasing force of the resilient element 275 (and not the combined bias of both
the resilient
elements 275, 162) to alter the locking assembly 190 from the locked state to
the unlocked state.
This is different than the actuation force applied to the actuator 160, which
must overcome the
combined bias of both the resilient elements 275, 162 to alter the locking
assembly 190 from the
locked state to the unlocked state.
[00115] The locking component 155 continues to ride along the cam surface 179
(and rotate the
locking member 170) until the locking component 155 is aligned with the
engagement feature
172. Once this happens, the bias of resilient element 275 rotates the locking
member 170 back
into the locked state, thereby forcing the locking component 155 into
engagement with the
engagement feature 172, as shown in FIG. 30.
[00116] Generally speaking, the locking bar 150 extends from a first end 151
that is pivotably
coupled to the first side rail 110 to a second end 152 that is slidably
coupled to the locking rung
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140 within the track 145 of the locking rung 140. With the ladder 100 in the
load bearing ladder
state (as shown in FIG. 9), the locking bar 150 extends obliquely relative to
the first and second
axes A-A, B-B (and hence also relative to the first and second side rails 110,
120). As described
above, the locking bar 150 comprises a locking component 155 that both slides
within the track
145 and engages the locking member 170 to lock the ladder 100 in the load
bearing ladder state.
In the exemplified embodiment, the locking component 155 is a rod that nests
within channels of
the track 145 located on opposing sidewalls so that the locking bar 150
remains coupled to the
locking rung 140 regardless of the specific position of the locking component
155 relative to the
locking rung 140. Thus, regardless of whether the ladder 100 is in the load
bearing ladder state
or the rail-to-rail collapsed state (FIG. 10), the locking bar 150 remains
slidably coupled to the
locking rung 140.
[00117] In FIG. 9, the ladder 100 is in a straight ladder configuration. In
this configuration, the
first and second side rails 110, 120 are spaced apart from one another by a
first distance Dl. In
the straight ladder configuration, the ladder 100 is ready for use as a
conventional ladder. The
ladder 100 in this configuration is very stable for use.
[00118] As mentioned above, the actuator 160 is operably coupled to the
locking member 170.
In the exemplified embodiment, the actuator 160 is operably coupled to the
locking member 170
via the cable 180 that extends along the first side rail 110, but other
structural arrangements for
this coupling may be possible in alternative embodiments. The actuator 160 is
alterable between
a first state, as shown in FIGS. 9 and 15, whereby the locking member 170 is
coupled to the
locking bar 150 so that the locking assembly 190 is in a locked state, and a
second state, as
shown in FIG. 19 described below, whereby the locking member 170 is decoupled
from the
locking bar 150 so that the locking assembly 190 is in an unlocked state. In
the exemplified
embodiment, the actuator 160 comprises a trigger 161 and pulling upwardly on
the trigger 161 in
a direction opposite gravity (or, in the exemplified embodiment, in a
direction towards the
second locking hinge 125) transitions the actuator 160 from the first state to
the second state.
Stated another way, the actuator 160 is actuated by pulling the trigger 161 in
a direction away
from the first end 121 of the second side rail 120 (and also away from the
locking rung 140 and
away from the locking bar 150).
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[00119] In the exemplified embodiment, the actuator 160 is located on an upper
region of the
first portion 123 of the second side rail 120 adjacent to the second locking
hinge 125. Thus, if
the first portion 123 of the second side rail 120 were divided into thirds,
the actuator 160 would
be located on the upper third of the first portion 123 of the second side rail
120. Furthermore, in
the exemplified embodiment, the actuator 160 is located on the outer surface
127 of the second
side rail 120. This positioning of the actuator 160 makes it very accessible
for actuation to alter
the ladder 100 between the non-collapsed and collapsed states. However, the
requirement that
the trigger 161 be pulled upwardly away from the locking rung 140 makes it so
that the trigger
161 is unlikely to be actuated accidently, which is a safety feature.
[00120] Referring to FIG. 10, as mentioned above the ladder 100 can be altered
into the rail-to-
rail collapsed state directly from the straight ladder configuration shown in
FIG. 9. Specifically,
by actuating the actuator 160, the locking bar 150 can be decoupled from the
locking member
170 so that the first and second side rails 110, 120 can be moved closer to
one another. During
this process, the non-locking rungs 130 and the locking rungs 140 pivot
relative to the first and
second side rails 110, 120 as the second side rail 120 is moved towards the
first side rail 110.
When in the collapsed state, the first and second side rails 110, 120 are
spaced apart by a second
distance D2 that is less than the first distance D1 and could be a distance of
zero in some
embodiments. Furthermore, in the collapsed state the second side rail 120 is
raised
longitudinally relative to the first side rail 110 so that the first ends 111,
121 of the first and
second side rails 110, 120 are offset from one another and the second ends
112, 122 of the first
and second side rails 110, 120 are offset from one another, as shown in FIG.
10.
[00121] FIG. 11 illustrates the ladder 100 in the step ladder
configuration. Specifically,
the first and second locking hinges 115, 125 can be actuated to allow the
first and second ladder
section 300, 400 to fold about the rotational axis C-C. As shown in several of
the figures, the
ladder 100 comprises a foot 199 coupled to the bottom ends of the first,
second, third, and fourth
side rails 110, 120, 410, 420. In order to qualify as a step ladder under ANSI
standards, the
ladder 100 has the required minimum flare per length of the rails. For
example, the ladder 100
has at least a 1.25 inch flare per foot of side rail. Thus, the feet 199 are
intended to increase the
base width of the first and second ladder section 300, 400 to satisfy the step
ladder safety
standards.
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[00122] Referring to FIGS. 24-26, another feature of the ladder 100 will be
described. In the
exemplified embodiment, the locking bar 150 comprises an aperture 156 through
which a portion
of the locking member 170 is exposed. More specifically, the portion of the
locking member 170
that is exposed through the aperture 156 comprises an indicium. FIG. 25
illustrates the first
indicia 157a that is visible through the aperture 156 when the locking
assembly 190 is in the
locked state. FIG. 18 illustrates the second indicia 157b that is visible
through the aperture 156
when the locking assembly 190 is in the unlocked state. In the exemplified
embodiment, the first
indicia 157a is an image of a padlock in a locked state and the second indicia
157b is an image of
a padlock in an unlocked state. Of course, the invention is not to be limited
to these specific
indicia. In other embodiments, the first indicia 157a may be a first color
(i.e., red) and the
second indicia 157b may be a second color (i.e., green) that is different than
the first color. The
first and second indicia 157a, 157b are meant to indicate to a user whether
the locking assembly
190 is in the locked state or the unlocked state so that the user knows
whether he can collapse the
ladder and/or safely use it in a conventional manner.
[00123] The ladder 100 may come in various different sizes, including, for
example without
limitation, five foot, seven foot, nine foot, eleven foot, etc., measured from
the first ends 111,
121 of the first and second rails 110, 120 to the second ends 112, 122 of the
first and second rails
110, 120. The ladder 100 could be less than five foot or more than eleven foot
in some
embodiments. The ladder 100 could be identical to that which has been
described herein
regardless of the length of the ladder, in some embodiments.
[00124] Referring briefly to FIGS. 27A-B, a ladder 100B is illustrated in
accordance with one
alternative embodiment whereby the ladder 100B is of a greater length than the
ladder 100. The
ladder 100B is structurally and functionally identical to the ladder 100
except that the ladder
100B includes two locking assemblies 390B and two actuators 160B. The locking
assemblies
390B and the actuators 160B are identical, both structurally and functionally,
to the locking
assembly 190 and the actuator 160 of the ladder 100 described above. Thus, a
detailed
description of these elements and other elements of the ladder 100B will be
omitted with the
understanding that the discussion above for the ladder 100 is applicable to
the ladder 300B
(unless otherwise stated below).
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[00125] In FIG. 27A, the ladder 100B is shown in the step ladder configuration
while, in FIG.
27B, the ladder 100B is shown in the folded configuration. As can be seen,
both the first ladder
section 300B and the second ladder section 400B comprises their own locking
assembly 190B
and actuator 160B. The locking assembly 190B and the actuator 160B on the
second ladder
section 100B operates the same for the third and fourth side rails 410B, 420B
as that discussed
above with respect to ladder 100 for the first and second side rails 110, 120.
[00126] A first one of the actuators 160B is located on the second side rail
120B while a second
one of the actuators 160B is located on the fourth side rail 420B. The
actuators 160B are
positione don the second and fourth side rails 120B, 420B so that upon the
ladder 100B being
altered into the folded configuration (FIG. 27B), the actuators 160B are at
least partially aligned
with one another in the axial direction. In the exemplified embodiment, the
actuators 160B are
fully aligned with one another. The first one of the actuators 160B is located
on an outer surface
of the second side rail 120B and the second one of actuators 160B is located
on an outer surface
of the fourth side rail 420B. In the folded configuration, the first and
second ones of the
actuators 160B are adjacent one another.
[00127] Although the actuators 360 for the two locking assemblies 390 are
shown positioned on
the same side of the ladder 300 in FIGS. 27A-B, they could be positioned on
opposing sides of
the ladder 300 in other embodiments. Increasing the number of locking
assemblies 390 increases
the stability of the ladder 300 to accommodate for the increase in length of
the ladder 300.
[00128] As used throughout, ranges are used as shorthand for describing each
and every value
that is within the range. Any value within the range can be selected as the
terminus of the range.
In addition, all references cited herein are hereby incorporated by referenced
in their entireties.
In the event of a conflict in a definition in the present disclosure and that
of a cited reference, the
present disclosure controls.
[00129] While the invention has been described with respect to specific
examples including
presently preferred modes of carrying out the invention, those skilled in the
art will appreciate
that there are numerous variations and permutations of the above described
systems and
techniques. It is to be understood that other embodiments may be utilized and
structural and
functional modifications may be made without departing from the scope of the
present invention.
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Thus, the spirit and scope of the invention should be construed broadly as set
forth in the
appended claims.
29
