U.S. patent application number 09/443831 was filed with the patent office on 2002-02-14 for structures having enhanced slip-resistant surfaces and associated methods.
Invention is credited to Maloney, Michael J., Smith, Troy G., Thom, Terrence N., Verdick, Nancy J..
Application Number | 20020018908 09/443831 |
Document ID | / |
Family ID | 23762362 |
Filed Date | 2002-02-14 |
United States Patent
Application |
20020018908 |
Kind Code |
A1 |
Smith, Troy G. ; et
al. |
February 14, 2002 |
STRUCTURES HAVING ENHANCED SLIP-RESISTANT SURFACES AND ASSOCIATED
METHODS
Abstract
A structure and associated methods are provided having enhanced
slip-resistant surfaces formed on the projections, recesses or
other surfaces of the structure to promote safe and stable movement
of people and/or objects on the structure. These structures can
include, for example, those materials commonly installed on
vehicles such as emergency vehicles. The methods associated with
the structure include roughening at least one smooth surface of the
structure to provide an enhanced slip-resistant surface. In
separate aspects of the method, for example, mechanical roughening
processes are disclosed which employ a set of two rollers, a single
roller or a punch die arrangement to roughen a smooth surface of a
structure. The enhanced slip-resistant structure can then be
installed on a vehicle or employed in a variety of other
applications where safe and stable movement of people and/or
objects is desirable.
Inventors: |
Smith, Troy G.; (Bettendorf,
IA) ; Thom, Terrence N.; (Bettendorf, IA) ;
Verdick, Nancy J.; (Geneseo, IL) ; Maloney, Michael
J.; (Bettendorf, IA) |
Correspondence
Address: |
Charles Q. Buckwalter Esq
Alcoa Inc
Alcoa Technical Center
100 Technical Drive
Alcoa Center
PA
15069-0001
US
|
Family ID: |
23762362 |
Appl. No.: |
09/443831 |
Filed: |
November 19, 1999 |
Current U.S.
Class: |
428/600 ;
428/687; 52/177 |
Current CPC
Class: |
E04F 11/16 20130101;
E04F 15/02172 20130101; Y10T 428/12389 20150115; B21D 13/04
20130101; B60N 3/048 20130101; Y10T 428/12993 20150115; E01C 11/24
20130101; E04F 11/112 20130101; B21H 8/005 20130101; B21B 1/227
20130101; E04F 15/02 20130101 |
Class at
Publication: |
428/600 ;
428/687; 52/177 |
International
Class: |
E04F 011/16; E04F
011/112 |
Claims
What is claimed is:
1. A structure having a frictional surface or surfaces thereon
comprising, at least one smooth surface provided with increased
slip resistance by a means for creating a frictional surface on
said smooth surface; and, said smooth surface selected from the
group consisting of a surface having at least one projection means
extending therefrom, a substantially continuous surface, a surface
having at least one recess means formed therein, a surface having a
combination of at least one projection means extending therefrom
and at least one recess means formed therein, and reasonable
combinations thereof.
2. The structure of claim 1, wherein said means for creating a
frictional surface is selected from the group consisting of
mechanical means, chemical means, electrical means, and reasonable
combinations thereof.
3. The structure of claim 2, wherein said electrical means includes
means selected from the group consisting of laser,
electro-discharge texturing, and reasonable combinations
thereof.
4. The structure of claim 1, wherein said structure is composed of
a material selected from the group consisting of aluminum, aluminum
alloy, steel, stainless steel, and reasonable combinations
thereof.
5. The structure of claim 4, wherein said aluminum alloy is an
alloy series selected from the group consisting of 2000, 3000,
5000, 6000, 7000 and reasonable combinations thereof.
6. The structure of claim 5, wherein said aluminum alloy is an
alloy series selected from the group consisting of 3003, 5086,
5052, 6061, 6013 and reasonable combinations thereof.
7. The structure of claim 1, wherein said structure is a fire truck
quality tread sheet composed of 3003 aluminum alloy having a temper
of H2X, wherein "X" is an integer.
8. The structure of claim 1, wherein said structure is selected
from the group consisting of extruded material, rolled material,
tread plate material and reasonable combinations thereof.
9. The structure of claim 1, wherein the height of said projection
means is about 0.025 to 0.100 inches.
10. The structure of claim 1, wherein the width of said projection
means is about 0.25 to 0.375 inches.
11. The structure of claim 1, wherein the length of said projection
means is about 0.85 to 1.3 inches.
12. The structure of claim 1, wherein the height of said projection
means is at least about 10% of the width of said projection
means.
13. The structure of claim 1, wherein the height of said projection
means is at least about 20% of the thickness of said structure.
14. The structure of claim 1, wherein a center-to-center spacing
between any two individual projection means is about 1 to 1.5
inches.
15. The structure of claim 1, wherein at least about 20% to 50% of
the exterior surface of said structure has said projection means
formed thereon.
16. A method of forming a frictional surface on a structure to
provide said structure with enhanced slip-resistance, comprising:
a. providing a structure having at least one smooth surface
thereon, said smooth surface selected from the group consisting of
a surface having at least one projection means extending therefrom,
a substantially continuous surface, a surface having at least one
recess means formed therein, and a surface having a combination of
at least one projection means extending therefrom and at least one
recess means formed therein, and reasonable combinations thereof;
and, b. roughening said smooth surface to provide said structure
with a frictional surface having enhanced slip-resistance.
17. The method of claim 16, wherein said roughening step includes
passing said structure through a set of rollers having an embossing
roller for roughening said smooth surface of said structure with
said embossing roller.
18. The method of claim 16, wherein said roughening step includes
tensioning said structure against an embossing roller for
roughening said smooth surface of said structure.
19. The method of claim 16, wherein said roughening step includes
pressing a punch die having an embossing surface against said
smooth surface of said structure.
20. The method of claim 16, wherein said roughening step includes
employing chemicals to roughen said smooth surface of said
structure.
21. The method of claim 16, wherein said roughening step includes
cladding said smooth surface of said structure.
22. The method of claim 16, wherein said roughening step includes
using laser means for roughening said smooth surface of said
structure.
23. The method of claim 16, wherein said roughening step includes
using electro-discharge texturing to roughen said smooth surface of
said structure.
24. The method of claim 16, further including the step of
installing structure plate on a vehicle after performing said
roughening step.
25. The method of claim 24, wherein said vehicle is an emergency
vehicle.
26. A structure roughened in accordance with the method of claim
16.
27. A structure, comprising: first and second sides; and, at least
one button formed on said first side of said structure having a
friction bearing surface produced thereon by roughening means to
provide enhanced slip resistance to said structure.
28. The structure of claim 27, wherein said structure is
substantially flat.
29. The structure of claim 27, wherein said second side of said
structure is a substantially continuous smooth surface.
30. The structure of claim 27, wherein said button is a recess
extending below the exterior surface of said first side of said
structure.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to forming enhanced
slip-resistant surfaces on structures. The present invention more
particularly relates to methods for producing enhanced
slip-resistant surfaces on structures to provide increased friction
for a user who is walking, running or otherwise moving a body or an
object across the slip-resistant surface.
[0003] 2. Background Information
[0004] It has been known in the art to provide various kinds of
materials having projections or recesses formed thereon in a
regular pattern or an irregular configuration to avoid slips, falls
and other accidents normally caused by walking, running or
otherwise moving on a smooth surface.
[0005] Extruded and rolled materials can be provided with buttons
to provide friction-bearing surfaces for movement such as walking.
Examples of such materials can be readily seen in numerous
applications. A walkway bridging the space between the deck of a
boat and a dock area is one example where a buttoned surface can be
employed on tread plate material to improve stability and provide
friction for movement by individuals entering and exiting the boat.
Another example can be seen on the bumper portion of a conventional
pick-up truck: a buttoned surface on the bumper provides a
frictional surface for an individual climbing on the bumper, for
example, to access the rear portion of the truck. Still another
example is a set of stairs used for accessing airplanes: these
metal stairs are the type usually mounted on wheels and positioned
in front of the airplane passenger door. Such metal stairs have
steps with buttoned surfaces thereon for providing frictional force
to those entering and leaving the airplane.
[0006] Another example of the use of buttoned or friction-bearing
surfaces can be seen in scaffolding for performing maintenance such
as cleaning the windows on relatively large buildings. The
horizontal portion of the scaffolding can have a buttoned surface
to resist accidental slips and falls of workers performing
maintenance on the building. Conventional bleachers, such as those
used by fans at sporting events, can possess buttoned surfaces to
promote stability while fans travel to and from seats in the
bleachers. In the manufacturing or industrial setting, friction
bearing surfaces can be advantageous for applications where fluid,
for example, is employed in production processes and is spilled
onto a walking surface thereby creating a potential slip-and-fall
hazard. Friction bearing surfaces can also be utilized on loading
ramps for moving equipment, boxes, livestock and the like to and
from vehicles such as trucks or cargo containers.
[0007] It can therefore be understood from these examples that
there are numerous and varied applications in which a buttoned
and/or friction bearing surface is advantageous for walking or
other movement. However, structures having only buttons formed
thereon, while used to permit movement of individuals and objects
on these materials, lack an enhanced slip-resistant surface that
would further promote safety and stability of movement on the
structures.
[0008] With regard to vehicles, tread plate material with a
buttoned surface installed on a fire truck can resist "slip and
fall" injuries experienced by fire fighters. Such injuries can be
caused by the fire fighter falling or slipping on the tread plate
while working on the truck, such as while accessing water valves
and hoses during a fire fight. Bright aluminum tread plate is
particularly popular with fire truck and emergency vehicle
manufacturers due to its aesthetic appearance among other
qualities. It has been known to provide tread plate with a Fire
Truck Quality (FTQ) tread which has been developed for its bright
and reflective surface, uniform appearance and consistent button
pattern. Consistent patterns are important for matching newly
installed tread plate to the patterns installed on existing
vehicles.
[0009] The National Fire Protection Agency (NFPA) has established
slip resistance requirements for horizontal walking surfaces used
by fire trucks as provided in its NFPA Standards for Automotive
Fire Apparatus (1999 ed.). Concern for accidents involving fire
fighters on fire truck apparatus, in particular, resulted in a
study of the slip-resistance characteristics of various tread plate
and walking surface materials.
[0010] The NFPA studied conventional aluminum alloy tread plate
materials as well as other materials proposed for use on fire
trucks. The test surfaces of these materials included several
varieties of solid and perforated surfaces. The materials also
included aluminum, wood and steel materials. In the study, a
polished diamond plate material with punched circles was stated to
seem very abrasive; however, several fire fighters commented that
this material could cause tripping and expressed concern that a
fall on this type of surface could cause serious injury. Other
surfaces judged in the study included a material described as a
pebble-textured rubber that was deemed unsafe when wet. In
addition, the study concluded that a material which included paint
with a sand-based abrasive applied to wood was also unsafe when
wet.
[0011] Conventional aluminum tread plate usually does not meet the
aforementioned NFPA slip resistance requirements, particularly
under wet conditions. The traditional aesthetic qualities of tread
plate, including its pattern uniformity, relatively low button
height, smooth base surface and smooth button tops can contribute
to a slip-resistance level that may not meet the NFPA slip
resistance requirements.
[0012] There is a need, therefore, for an improved surface for
individuals moving and working around vehicles, work areas,
recreational places and numerous other applications in which a
friction-bearing surface is advantageous. Such an improved surface
is especially needed on wet or slippery surfaces. The prior art has
not sufficiently addressed the need for a structure and associated
methods for enhancing the slip-resistant qualities of existing
materials, particularly aluminum tread plate, employed on vehicles,
work areas and in a multitude of other applications.
SUMMARY OF THE INVENTION
[0013] The present invention has met and/or exceeded the
above-described needs. The present invention provides a structure
and associated methods including means for forming a friction
bearing surface on the smooth surface or surfaces of a structure to
improve its slip resistance characteristics under both wet and dry
conditions.
[0014] The means of forming a roughened surface on a smooth surface
of the structure of the present invention can include mechanical,
chemical, and electrical apparatus and methods and reasonable
combinations thereof. One mechanical method embodiment includes the
step of providing a piece of material having at least one button
formed thereon. This mechanical method also includes the step of
roughening a smooth surface or surfaces of the structure.
Mechanical roughening can also be performed by mechanical apparatus
such as by embossing the smooth surfaces of the structure with a
set of rollers, a single roller or a punch die arrangement. It can
be understood by those skilled in the art that employing a suitable
apparatus or method that involves mechanical and chemical methods
as well as clad, laser and electro-discharge texturing (EDT) can
provide a friction bearing surface having enhanced slip-resistant
qualities.
[0015] The structure employed in the present invention is composed
of aluminum, aluminum alloy, steel, stainless steel and reasonable
combinations thereof or any other material on which a projection
means such as a button can be formed and/or in which a recess can
be formed. A suitable material can also be selected based on the
particular roughening process or apparatus that is desired. It is
also understood that any material which is suitable for processing
in a roller or punch die setting, for example, or by the other
roughening methods disclosed herein is suitable for application to
the present invention. The preferred aluminum alloys for use in the
structure of the present invention are alloys included in the 2000,
3000, 5000, 6000 and 7000 series and reasonable combinations
thereof. In addition, a material can have any temper that is
consistent with practice of the present invention by one skilled in
the art.
[0016] The shape of the projection means formed on a structure can
be generally diamond, oval, circular or rectangular shaped or a
combination thereof and configured in either a regular, ordered
pattern or an irregular configuration or reasonable combinations
thereof. It can be appreciated that any suitable pattern that
presents a smooth surface that can be roughened by the means
discussed herein can be employed in the present invention.
[0017] In one embodiment of the present invention, a structure is
produced that is a piece of material including first and second
sides, wherein at least one button is formed on the material that
has a roughened surface formed thereon to provide a friction
bearing surface, such as for walking. The first side of the
roughened structure is substantially flat and the second side of
the piece of metal is provided as a substantially continuous smooth
surface.
[0018] It is therefore an object of the present invention to
provide a tread plate with a surface that meets and/or exceeds
National Fire Protection Agency slip-resistance requirements.
[0019] It is a further object of the present invention to provide a
roughened structure that has sufficient impact resistance for use
as a walking or running surface.
[0020] It is a still further object of the present invention to
provide a pattern on a roughened structure that is aesthetically
pleasing.
[0021] It is a still further object of the present invention to
provide a roughened tread plate button pattern that suitably
matches existing tread plate patterns.
[0022] It is a still further object of the present invention to
provide a roughened structure that remains mechanically formable in
subsequent manufacturing processes.
[0023] It is a still further object of the present invention not to
substantially adversely impact the pre-roughening corrosion
resistance characteristics of the structure.
[0024] These and other objects of the present invention will be
more fully understood from the following description of the
invention and by reference to the figures and claims appended
hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is an isometric view of a structure;
[0026] FIG. 2 is an enlarged isometric view of a section of FIG.
1;
[0027] FIG. 3 is an isometric view of a set of rollers mechanically
roughening a structure in accordance with an embodiment of the
present invention;
[0028] FIG. 4 is an isometric view of a single roller roughening a
structure in accordance with an embodiment of the present
invention;
[0029] FIG. 5 is an isometric view of a punch die for roughening a
structure in accordance with an embodiment of the present
invention;
[0030] FIG. 6 is an isometric view similar to FIG. 5, except
showing the embossing surface on the punch die;
[0031] FIG. 7 is an isometric view of an embodiment of a roughened
structure of the present invention;
[0032] FIG. 8 is an enlarged fragmentary cross-sectional view of a
portion of FIG. 7;
[0033] FIG. 9 is an isometric view of an embodiment of a roughened
structure of the present invention;
[0034] FIG. 10 is an enlarged fragmentary cross-sectional view of a
portion of FIG. 9;
[0035] FIG. 11 is an isometric view of an embodiment of a roughened
structure of the present invention;
[0036] FIG. 12 is an enlarged fragmentary cross-sectional view of a
portion of FIG. 11;
[0037] FIG. 13 is an isometric view of an embodiment of a roughened
structure of the present invention; and,
[0038] FIG. 14 is an enlarged fragmentary cross-sectional view of a
portion of FIG. 11.
DESCRIPTION OF THE EMBODIMENTS
[0039] As used herein, the term "structure" includes any object or
material which is capable of having a friction bearing surface
formed thereon and includes, for example, rolled materials,
extruded materials and tread plate materials.
[0040] As used herein, "slip resistance" is generally defined as
the ability of one surface to engage another surface in
surface-to-surface contact thereby limiting motion between the
surfaces so engaged. A slip resistance measurement, expressed as a
numerical value, is an indication of the frictional forces
generated by such surface-to-surface contact. The slip resistance
measurement approaches zero as the generated frictional forces
become practically non-existent and approaches unity as the
generated frictional forces become relatively high.
[0041] Slip resistance can therefore be expressed as a measured
quantity, obtained through use of various measurement devices.
Examples of such devices include the tester sold under the "English
XL" trade designation, as referred to in ASTM F1679, Standard Test
Method for Using a Variable Incidence Tribometer; or, the tester
sold under the "Brungraber Mark II" trade designation, referred to
in ASTM F 1677, Standard Test Method for Using a Portable
Inclinable Articulated Strut Slip Tester (PLAST).
[0042] Slip resistance can also be referred to as a perceived
quality, documented in various studies on walking surfaces, as
reported by the NFPA Committee on Fire Apparatus: Firefighter Tread
Plate Slip Resistance Study (Marletta, William, Ph.D., CSP).
[0043] The term "smooth" as applied herein is a surface
characteristic wherein the "smooth" surface has slip resistance
qualities that are relatively less desirable than a surface having
enhanced slip resistance qualities.
[0044] As used herein, the term "roughening" includes alteration of
a smooth or substantially smooth surface to provide raised portions
or projections and/or recessed areas on that surface, such as on a
smooth surface of a button formed on a tread plate, for
example.
[0045] As used herein, the term "button" includes any projection or
nodule reading above, or any recessed area extending below, or any
reasonable combination thereof, the exterior of a structure.
[0046] As used herein, the term "pattern" can refer to an ordered,
regular pattern or an irregular configuration or reasonable
combinations thereof, such as in the context of a particular
"pattern" of buttons formed on a structure.
[0047] As used herein, an "extruded" product is one that has been
formed by direct or indirect pressure applied to a material to
force the material through a die to provide a product that
substantially matches the shape of the die. A "rolled" product is
one which has been formed by passing material through a set of
rollers that results in a reduction of thickness of the product and
which has a thickness in the range from about 0.05 to 0.75 inches,
which range includes values defined by the following set: {0.050,
0.051, 0.052, 0.053, . . . , 0.748, 0.749, 0.75}.
[0048] As used herein, the term "plate" includes a solid material
having a thickness of about 0.250 to 0.750 inches, including the
thickness values defined by the data set: {0.250, 0.251, 0,252,
0.253, . . . , 0.748, 0.749, 0.750}. The term "sheet" as used
herein includes thicknesses of solid materials in the range of
about 0.03 to less than 0.250 inches, which range includes the
values in the data set: {0.031, 0.032, 0.033, . . . , 0.247, 0.248,
0.249} and values less than 0.250.
[0049] The term "tread" as used herein in conjunction with another
term such as "plate" or "sheet" includes a material having a
textured, imprinted or other raised surface portion thereon and
also optionally having a friction bearing surface formed thereon,
such as by a roughening method.
[0050] As used herein, the term "vehicle" can include any suitable
transportation apparatus including an automobile, truck, airplane,
train, or any other apparatus on which, or in association with
which, it is desirable to have walking surfaces installed. As used
herein, the term "emergency vehicle" includes fire trucks,
ambulances, tow trucks, wreckers, and other similar vehicles.
[0051] Referring now to FIG. 1, in the form shown, the present
invention provides a structure that can be provided as a piece of
tread plate 2 having a thickness T. The tread plate 2 is provided
with a plurality of projections or buttons 4 positioned thereon.
The buttons 4 are preferably formed integrally with the exterior
surface 6 of the tread plate 2 such as by a separate conventional
forming process. The buttons 4 are formed into a patterned
arrangement which, it will be understood, can be a regular or
irregular configuration including one or more identically or
differently configured shapes or reasonable combinations thereof.
These shapes can include, for example, generally diamond (as
shown), generally oval, generally circular, or generally
rectangular and reasonable combinations thereof among other
possible, suitable shapes. The structure is preferably composed of
a material selected from the group consisting of aluminum, aluminum
alloy, steel and stainless steel. The preferred alloys for use in
the present invention are aluminum alloys including the 2000, 3000,
5000, 6000 and 7000 series as registered with the Aluminum
Association. Aluminum alloys more preferably employed in the
present invention include 3003, 5086, 5052, 6061 and 6013. In
addition, for Fire Truck Quality (FTQ) material, an aluminum alloy
of 3003 having a temper of H22 is most preferred for use on
emergency vehicles such as fire trucks. The FTQ material can also
be provided with a temper of H2X, wherein the "X" portion of "H2X"
is an integer.
[0052] Referring now to FIG. 2, each of the buttons 4 has a body 8
having at least one smooth surface 10. The buttons 4 have a typical
height H of about 0.025 to 0.100 inches. The buttons have a typical
length L of about 0.85 to 1.30 inches and a typical width W of
about 0.25 to 0.375 inches. The height H of the buttons is
preferably at least about 10% to 25% of the width W of the buttons.
The height H of the buttons is preferably at least about 20% to 40%
of the thickness T of the tread plate 2. The center-to-center
spacing CC between the buttons 4 is about 1 to 1.5 inches. In a
preferred embodiment of the present invention, at least about 20%
to 50% of the exterior surface 6 of the tread plate 2 has buttons 4
formed thereon.
[0053] Referring again to FIGS. 1 and 2, the preferred method of
the present invention includes providing a structure such as tread
plate 2 having a plurality of buttons 4 formed thereon. As
discussed herein, this method includes roughening at least the
exterior surface 6 or the smooth surfaces 10 of the buttons 4 to
provide the tread plate 2 with an enhanced, slip-resistant surface.
In certain embodiments of the present invention, the roughening
step can be performed by embossing at least one of the surfaces 10
of the buttons 4. It can be understood that other means for
roughening a surface of a structure could also be employed. These
other means include utilizing suitable mechanical and chemical
methods as well as clad, laser and electro-discharge texturing
methods known to those skilled in the art. Those skilled in the art
can readily appreciate the numerous and varied methods and
apparatus that can be used to roughen a structure consistent with
the teachings of the present invention.
[0054] In one embodiment of the method of the present invention
shown more particularly in FIG. 3, the roughening step is performed
on a set of rollers 20. A roller 22 is positioned adjacent to a
bottom roller 24 to form a bite region 26 between the rollers
22,24. The top roller 22 is provided with a surface having a
plurality of projections forming a pattern 28 thereon to provide
the top roller 22 as an embossing roller. The bottom roller 24 is
preferably provided as a smooth roller as shown.
[0055] In operation, a structure such as piece of material 30
having projections such as buttons 32 formed thereon is introduced
by a conventional apparatus or method to the bite region 26 of the
set of rollers 20. As the material 30 passes through the set of
rollers 20 the pattern 28 of the top or embossing roller 22
embosses or engraves the material 30 providing roughened buttons 34
for facilitating enhanced slip-resistant surfaces on the material
30. The set of rollers 20 is operated by a conventional apparatus
suitable for exerting force on the material 30 sufficient to form
projections on the roughened buttons 34. It will be understood that
one roller 22 rotates in a counterclockwise direction while the
other roller 24 rotates in a clockwise direction to enable the set
of rollers 20 to move the material 30 through the bite region of
the set of rollers 20. It can also be understood that the
particular direction of rotation of the rollers 22,24 is not
critical to the method of the present invention except that such
rotation should be effective in passing the material 30 through the
set of rollers 20.
[0056] In another embodiment of the method of the present invention
shown more particularly in FIG. 4, the roughening step is performed
on a single roller 40 having an embossing surface 42 thereon. The
embossing surface 42 includes a plurality of projections arranged
in either an ordered or an irregular pattern on the surface 42. A
structure such as material 44 having a pattern 46 of a plurality of
projections such as buttons 48 formed thereon is pressed against
the embossing surface 42 of the roller 40. It can be understood
that sufficient force to roughen surfaces on the buttons 48 can be
generated between the pattern 46 and the embossing surface 42 by a
suitable apparatus or method (not shown). It can also be
appreciated by one skilled in the art that the embossing surface 42
can be configured such that the surfaces on the material 44 between
the buttons 48 are roughened and the buttons 48 themselves are not
roughened.
[0057] In operation, referring again to FIG. 4, the roller 40
rotates in a clockwise direction to impinge at least a portion of
the plurality of buttons 48 on the material 44 against the
embossing surface 42 of the roller 40. Because of the tensioned
relationship between the roller 40 and the material 44, the buttons
48 are roughened by their impingement against the embossing surface
42 of the roller 40. The roughening of smooth surfaces of the
buttons 48 yields a pattern of roughened buttons 50 on the
processed portion of the material 44. It can be understood that the
single roller alternatively can be positioned on top of the
material, provided that sufficient pressure exists to roughen the
buttons when the material and the roller are positioned in contact
and moved relative to each other.
[0058] In another embodiment of the method of the present invention
shown more particularly in FIGS. 5 and 6, the roughening step
includes pressing a punch die 60 having an embossing surface 62
against the projections such as buttons 64 formed on a structure
such as material 66. In operation, the material 66 is sandwiched
between the punch die 60 and a stationary or fixed backing plate
68. The punch die 60 is preferably moveable by a suitable means to
permit removal and insertion of the material 66 between the punch
die 60 and the backing plate 68. The punch die 60 is applied with
sufficient force against the buttons 64 on the material 66 to
provide smooth surfaces on the buttons 64 with a roughened,
friction bearing surface that imparts enhanced slip-resistance to
the material 66. The force applied against the punch die 60 coupled
with the reaction force generated by the backing plate 68 provides
the necessary pressure to effect roughening for the smooth surfaces
of the buttons 64.
[0059] In any of the previous embodiments, once the roughening or
embossing step is completed, preferably at least about 25% to 100%,
more preferably about 50% to 100%, and most preferably about 90% to
100%, of the exterior surface of the structure has roughened
buttons or another enhanced slip-resistant surface formed thereon.
In addition, certain embodiments of the present invention also
encompass installing the enhanced slip-resistant structure on a
vehicle after the roughening step is performed. This installation
preferably involves installing the structure on an emergency
vehicle such as a fire truck. It can be appreciated that the
enhanced slip-resistant structure is preferably installed on a
portion of the vehicle where workers walk or perform other
functions or where objects are moved.
[0060] Referring now to FIGS. 7 and 8, a structure such as material
80 processed by the method of the present invention is provided
with projections such as roughened buttons 82 formed thereon. The
structural integrity of the material 80 remains substantially the
same before and after the roughening step is performed. As shown in
FIG. 8, projections 84 are formed on the buttons 82 to provide
friction-bearing surfaces that possess enhanced slip-resistant
qualities. The characteristics of these projections 84 are a
function of the particular embossing surface pattern selected for
roughening and/or the roughening method or apparatus used to form
the projections 84. It can be appreciated that these factors affect
the resulting slip-resistance measurement that the roughened
surface possesses.
[0061] Referring again to FIGS. 7 and 8, a structure having an
enhanced slip-resistant surface formed by any of the previously
discussed embodiments includes a piece of material 80 having
projections such as buttons 82 having roughened surfaces formed
thereon. The piece of material 80 has a first side 86 and a second
side 88. The buttons 82 have enhanced slip-resistant surfaces 90
that are formed on the first side 86 of the piece of material 80.
The roughened, slip-resistant surfaces 90 on the roughened buttons
82 can also form patterns on the buttons 82. The roughened material
80 has a substantially flat surface on its second side 88 that is
preferably a substantially continuous smooth surface. It can be
understood that the material 80 can have all (as shown) or only a
portion of its buttons 82 with enhanced slip-resistant surfaces 90
formed thereon.
[0062] Referring now to FIGS. 9 and 10, a structure such as piece
of material 96 can have recesses 92 formed below the exterior
surface 94 of the piece of material 96. It can be appreciated that
such recesses 92 can be formed into the piece of material 96 by any
suitable means. The exterior surface area 94 which surrounds the
recesses 92 can be roughened by an apparatus and/or associated
method previously discussed herein to provide the exterior surface
94 of the piece of material 96 with a friction bearing surface or
surfaces as shown.
[0063] Referring now to FIGS. 11 and 12, a structure such as piece
of material 100 (without projections) can be roughened by the
methods and apparatus of the present invention. As shown, this
results in a friction bearing surface 102, possessing enhanced
slip-resistant properties, formed across a substantial portion of
the exterior surface of the piece of material 100.
[0064] Referring now to FIGS. 13 and 14, a structure such as piece
of material 116 can have buttons 112 formed above the exterior
surface 114 of the piece of material 116. The exterior surface area
114 which surrounds the recesses 112 is roughened by an apparatus
and/or associated method previously discussed herein. It can be
appreciated, for the form of the invention as shown, that the
roughening apparatus and/or method is configured so that the
buttons 112 remain substantially unroughened, while the exterior
surfaces 114 are substantially roughened. This roughening provides
the exterior surface 114 of the piece of material 116 with a
friction bearing surface or surfaces as shown in FIGS. 13 and
14.
[0065] It can be understood in the present invention that the
pattern formed on the buttons of the tread plate product can be
selected from among a variety of different patterns, and that the
pattern need not be formed in a regular, ordered array. It can also
be appreciated that metal flow caused by the mechanical pressure
exerted between an embossing surface and the button pattern can
result in projections formed around the depressions formed in the
material, on the buttons formed in the material, in the surface
areas therebetween or reasonable combinations thereof. These
projections are formed by metal material flowing up and around the
periphery of a depression formed in a roughened surface.
EXAMPLES
[0066] The following examples are presented for illustration
purposes only and are intended to assist in disclosing the present
invention to those skilled in the art and not to limit the scope of
the present invention:
[0067] Tread sheet material was supplied in cut-to-length sheets,
ranging typically from 96" to 240" in length and from 48" to 84" in
width. The thickness of the tread sheet material was from 0.058" to
0.188", although emergency vehicles typically use from 0.100" to
0.188" thickness material. Table I (below) summarizes dimensions
and average slip values for a variety of tread sheet products used
in this example. The slip resistance values for these materials
were obtained by testing the tread plate in 4 directions with an
ENGLISH brand XL-slip tester. Slip resistance was tested with an XL
Slip Resistance Tester (See, e.g., U.S. Pat. No. 5,259,236) in
accordance with ASTM F1679, Standard Test Method for Using a
Variable Incidence Tribometer.
1TABLE I Button Average Slip Average Slip Tread Plate Button Height
Length Resistance Resistance Description (Typical) (Typical) (Dry)
(Wet) 5 Bar tread 0.036" 1.140" 0.517 0.549 Alcoa FTQ 0.066" 1.193"
0.601 0.563 Alcoa C300 0.088" 1.267" 0.647 0.563 1 Bar tread 0.060"
1.175" 0.614 0.510 Competitor 0.047" 1.169 0.677 0.571 Alcoa C300a
0.076" 0.907" 0.689 0.593
[0068] In application of this method embodiment of the present
invention, a manual roughening method for roughening buttons formed
on tread plate was performed on existing Alcoa FTQ tread plate and
Alcoa C300 tread plate. The button pattern on these tread plates
was manually roughened with the head of a framing hammer to create
a roughened surface on the top surfaces of the buttons. As shown
more particularly in Table II, the effect of roughening the buttons
is demonstrated with respect to relative changes in slip resistance
values:
2TABLE II Average Slip Tread Plate and Resistance Average Slip
Resistance Roughening Method (Dry) (Wet) Alcoa FTQ 0.713 0.684
Manual Medium Pattern Alcoa FTQ 0.890 0.834 Manual Heavy Pattern
Alcoa C300 bright 0.995 0.944 Manual Heavy Pattern
[0069] As can be readily seen from Table II, the roughening method
of the present invention provides substantial improvements in slip
resistance over existing or non-roughened tread plate materials and
patterns. The original Alcoa FTQ tread plate material, for example,
improved from slip resistance values of 0.601 (dry) and 0.563 (wet)
to values of 0.890 (dry) and 0.834 (wet), after application of the
"Manual Heavy Pattern" roughening method.
[0070] In another example of the present invention, different
pattern configurations of a tread plate material were machined by
the rolls of a standard and conventional jeweler's mill to simulate
normal production. Each of these rolls was approximately 4.5" wide
with a diameter of about 2.5". The data included in Table III
(below) includes a sampling of average slip resistance measurements
obtained from variously patterned tread plate materials processed
through the jeweler's mill roughening method. These tread plate
materials included a variety of different patterns, thicknesses,
material composition and reasonable combinations thereof.
3 TABLE III Average Slip Resistance Pattern (Wet) Pattern 1 0.625
Pattern 2 0.673 Pattern 3 0.835 Pattern 4 0.913 Pattern 4a 0.925
Pattern 7 0.705 Pattern 8 0.678 Pattern 8838 0.820 Pattern 8936
0.813 Pattern 9403 0.755
[0071] Referring to Table III, the measurements for this example
were obtained using an ENGLISH XL brand slip resistance tester as
previously discussed. As shown, the pattern designated "4a"
provides an average wet slip resistance reading of 0.925, which is
better than conventional, unroughened tread plate materials.
[0072] Therefore, the present invention provides a structure and
associated methods for resisting slip and fall type accidents by
providing an enhanced slip-resistant surface on the structure when
used as a walking surface or for other similar movement including
movement of objects thereon.
[0073] Whereas particular embodiments of this invention have been
described above for purposes of illustration, it will be evident to
those skilled in the art that numerous variations of the details of
the present invention may be made without departing from the
invention as defined in the appended claims.
* * * * *