U.S. patent application number 13/758081 was filed with the patent office on 2013-06-06 for scaffold system and method.
This patent application is currently assigned to NEXT GENERATION SCAFFOLD SERVICES INC.. The applicant listed for this patent is Next Generation Scaffold Services Inc.. Invention is credited to Steve Howard Thacker.
Application Number | 20130142564 13/758081 |
Document ID | / |
Family ID | 44308116 |
Filed Date | 2013-06-06 |
United States Patent
Application |
20130142564 |
Kind Code |
A1 |
Thacker; Steve Howard |
June 6, 2013 |
SCAFFOLD SYSTEM AND METHOD
Abstract
A scaffold system and method having a hollow horizontal member
with an internal wedge head at each end thereof, and internal wedge
assembly with an external handle, and a vertical member having
affixed in coaxial alignment therewith at least one grid patterned
rosette. Each internal wedge head at the end of the horizontal
member is configured to couple to the grid patterned rosette
coupled to the vertical member substantially simultaneously using
the wedge assembly mechanism.
Inventors: |
Thacker; Steve Howard;
(Humble, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Next Generation Scaffold Services Inc.; |
Las Vegas |
NV |
US |
|
|
Assignee: |
NEXT GENERATION SCAFFOLD SERVICES
INC.
Las Vegas
NV
|
Family ID: |
44308116 |
Appl. No.: |
13/758081 |
Filed: |
February 4, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12930921 |
Jan 20, 2011 |
8393439 |
|
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13758081 |
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61337156 |
Jan 26, 2010 |
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61343087 |
Apr 23, 2010 |
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Current U.S.
Class: |
403/187 ;
29/426.1; 29/428 |
Current CPC
Class: |
E04G 7/02 20130101; Y10T
403/30 20150115; Y10T 403/73 20150115; E04G 7/307 20130101; E04G
7/32 20130101; Y10T 29/49815 20150115; Y10T 403/39 20150115; Y10T
403/70 20150115; Y10T 29/49826 20150115 |
Class at
Publication: |
403/187 ; 29/428;
29/426.1 |
International
Class: |
E04G 7/02 20060101
E04G007/02 |
Claims
1. A system for coupling a horizontal member to a vertical member
of a scaffold, comprising: a horizontal member and a wedge head
attached to each end of the horizontal member, the horizontal
member; and an internal wedge assembly within the horizontal member
and wedge head, the internal wedge assembly having a wedge portion,
the end of which partially or wholly extends and retracts from the
end of the horizontal member and wedge head.
2. The system of claim 1, further comprising a rosette having a set
of radially arranged cut-outs, the vertical member affixed in
coaxial alignment with the rosette; the internal wedge head having
mating elements corresponding to the radially arranged cut-outs of
the rosette, wherein, when the mating elements of the internal
wedge head are received in the radially arranged cut-outs of the
rosette, the internal wedge assembly, when actuated, causes the
wedge portion to rigidly join the horizontal member to the
rosette.
3. The system of claim 1, further comprising the internal wedge
assembly having at least one wedge portion at the first end of a
rod, the second end of the rod rotatably coupled to a crank/cam
assembly.
4. The system of claim 3, further comprising a handle external to
the horizontal member being rotatably coupled to the crank/cam
assembly.
5. The system of claim 3, further comprising the internal wedge
head having a wedge bore through which the wedge portion wholly or
partially extends or retracts when the crank/cam assembly is
actuated.
6. The system of claim 3, wherein the crank/cam assembly is
positioned within hollow tubing of horizontal member and further
comprises a rotatable crank axle, the ends of which rotatable crank
axle are rotatably coupled to the interior sides of horizontal
member, at least one end of which rotatable crank/cam axle extends
out of horizontal member orthogonally to the length of the
horizontal member so as to receive a handle.
7. The system of claim 6, in combination with a handle responsively
coupled to an external extension of the crank axle.
8. The system of claim 7, wherein the rotatable crank axle and
hence, the handle is positioned closer to one end of the horizontal
member as opposed to the other end.
9. A method of erecting a scaffold comprising the steps of:
positioning a horizontal member having a wedge head attached to
each end of the horizontal member; and causing a wedge portion
within an internal wedge assembly within the horizontal member and
wedge head to extend therefrom so as to couple the horizontal
member to a rosette affixed in a coaxial arrangement with a
vertical member.
10. A method of disassembling a scaffold comprising the steps of:
holding a horizontal member having a wedge head attached to each
end of the horizontal member; and causing a wedge portion within an
internal wedge assembly within the horizontal member and wedge head
to retract therein so as to decouple the horizontal member from a
rosette affixed in a coaxial arrangement with a vertical
member.
11. An apparatus for coupling a horizontal member to a vertical
member of a scaffold, comprising: a horizontal member having an
internal wedge assembly therein, a wedge portion configured to be
extendable from or retractable into an end of the horizontal
member.
12. The apparatus of claim 11, further comprising a vertical member
having a rosette affixed in coaxial alignment with the vertical
member, the wedge portion configured to be locked or unlocked onto
the rosette.
13. The apparatus of claim 11, further comprising a first wedge
portion extendable and retractable through a first end of the
horizontal member and a second wedge portion extendable and
retractable through a second end of the horizontal member.
14. The apparatus of claim 13, further comprising the first wedge
portion and second wedge portion being responsively coupled to a
handle external to the horizontal member via a crank/cam
assembly.
15. The apparatus of claim 14, further comprising a wedge head at
each end of the horizontal member, the wedge head having a wedge
bore through which each respective wedge portion wholly or
partially extends or retracts when the crank/cam assembly is
actuated.
16. The apparatus of claim 15, wherein the crank/cam assembly is
positioned within hollow tubing of horizontal member and further
comprises a rotatable crank axle, the ends of which rotatable crank
axle are rotatably coupled to the interior sides of horizontal
member, at least one end of which rotatable crank/cam axle extends
out of horizontal member orthogonally to the length of the
horizontal member so as to receive a handle.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/337,156 filed on Jan. 26, 2010, entitled
"GRIDLOCK SCAFFOLD APPARATUS AND METHOD" and U.S. Provisional
Application No. 61/343,087 filed on Apr. 23, 2010, entitled "HYBRID
SCAFFOLD SYSTEM" and is a Continuation of U.S. Regular application
Ser. No. 12/930,921 filed Jan. 20, 2011.
FIELD OF THE INVENTION
[0002] This invention relates to modular scaffolding systems that
are erected as impermanent structures to support platforms.
Scaffolding is used, inter alia, in the industrial, commercial,
petro-chemical, power source, general industry and residential
construction markets.
BACKGROUND
[0003] In 2008, the Bureau of Labor Statistics' Census of Fatal
Occupational Injuries (CFOI) reported 88 fatalities occurred in the
year 2007 related to the use of scaffolds and many more injuries.
Twenty-seven percent (27%) of the fatalities and many of the
injuries involved falls off of welded frame scaffolds over 25 feet
high during the installation of the scaffolds. Safety officials
recommend that scaffolding falls be pre-empted through the use of
sequential erection techniques. This involves installing guardrails
and standards at regular distances along the scaffold such that the
exposed platform edge is not greater than a bay length between
intervals. The use of safety harnesses or belts tethered to
guardrails during the erection process is also a recommended safety
practice. However, the use safety harnesses to deter fall injuries
during scaffold erection is quite limited due to the components
used in conventional scaffolds. The nature and design of
conventional scaffold components, as described herein,
disadvantageously do not allow the effective use of safety
harnesses during the erection process.
[0004] Tube and coupler scaffolds are so-named because they are
built from tubing connected by coupling devices. Due to their
strength, they are frequently used where heavy loads need to be
carried, or where multiple platforms must reach several stories
high. Components of scaffolds include vertical standards having
coupling rings or rosettes, horizontal components such as ledgers
and guardrails coupled to the coupling rings or rosettes, footings,
decks/platforms and diagonal braces. Their versatility, which
enables them to be assembled in multiple directions in a variety of
settings, also makes them difficult to build correctly.
[0005] Conventional scaffolding systems have various components.
FIG. 1 illustrates a supported scaffold 100 consisting of one or
more platforms supported by rigid support members such as poles,
tubes, beams, brackets, posts, frames and the like. More
specifically, the supported scaffold 100 includes the following
components: deck/platform 101, horizontal members, or ledgers 102,
vertical standards 103. Additional components include diagonal
braces to increase the stiffness and rigidity of the scaffold
100.
[0006] FIG. 2 is an illustration of a vertical standard 103.
Vertical standards are typically cylindrical tubes 200 comprised of
hot-dip galvanized steel or aluminum. A collar with an expanded or
reduced diameter or a spigot at either or both ends of the vertical
standard facilitates the joining of vertical standards from end to
end. Rosettes 201 are positioned and then welded or otherwise
attached along the tubes providing connections for horizontal
members and diagonal braces. The vertical standard can have from
one to 8 or more rosettes placed along the tubing using a
predetermined spacing between rosettes, for example, about every 20
inches.
[0007] FIG. 3 illustrates a ledger 102. A ledger is a horizontal
member that serves as both a guardrail and bracing element. The
ledger 102 is comprised of tubing 300, heads 301 and wedges 302.
Ledgers 102 are available in different lengths, depending on the
scaffolding bay length, deck type and load. It is the conventional
manner in which these ledgers are coupled to vertical standards
that contribute to scaffolding falls as further described herein.
Once the tubing on a level is installed, decks or platforms 101
made of, e.g., hot-dip galvanized steel, aluminum, wood or an
aluminum frame with plywood board are installed to allow workers to
traverse the scaffold 100 and install the guardrails (e.g., ledgers
102).
[0008] Referring now to FIG. 4, wedge 302 is shown being hammered
into the slot or gap of head 301 at the end of a ledger 102 so as
to couple it to the rosette 201 of the vertical standard 200. This
must be done by a worker first at the proximate end of the ledger
102 and then at the distal end of the ledger 102. However, as the
proximate end of the ledger 102 is being coupled to the vertical
standard using the wedge 302, the distal end of the ledger 102 is
free and uncoupled, that is, until the worker can traverse the
platform to the distal end of the ledger 102 and hammer in a wedge
302 at the distal end. During this time, the distal end of the
ledger 102 remains uncoupled from the vertical standard. Hence, if
the installer is harnessed to the ledger 102 and the scaffold tilts
toward the uncoupled, distal end, the installer may tumble down the
platform and the safety harness will exit the uncoupled end of the
ledger, providing no measure of safety to the installer.
[0009] A conventional rosette 500, as seen in FIG. 5, has a central
aperture 503 to receive the vertical tubing, four small openings
501A-D to facilitate right-angled connections and four larger
openings 502 A-D to facilitate connections at any angles.
Typically, a vertically and horizontally slotted head 504 coupled
to the end of a ledger is positioned with respect to the rosette
500 such that the horizontal slot of the head 504 is positioned
over and under the rosette 500 and the vertical slot of the head is
aligned with an aperture of the rosette 500. A wedge 302 is then
hammered into the vertical slot (or gap) to couple the ledger 102
via the head 504 to the vertical standard 103 via the rosette 500
using, inter alia, frictional force. Note that, disadvantageously,
until the wedge 302 is installed, there is significant play between
the rosette 500 and head of a horizontal member giving rise to
safety concerns. Furthermore, once installed, wedges often work
free when workers traverse the platform. When these wedges work
free, the scaffold can become unstable and collapse. Further, even
if the scaffold does not collapse, steel wedges, which, as seen in
the Figure, are not integrated into the head or the ledger, can
fall from the scaffold injuring workers below.
[0010] What is desired is a scaffolding apparatus and method that
is configured to couple both ends of a ledger (also referred to
herein as a horizontal member) to a vertical standard (also
referred to herein as a vertical member) simultaneously, and which
has an internal wedge assembly mechanism that allows a single
installer to insert and lock wedges at both ends of the horizontal
member substantially simultaneously to the vertical standard. The
invention provides such an apparatus and method.
SUMMARY
[0011] The invention comprises a scaffold apparatus and method that
overcomes the safety, rigidity, and labor issues inherent in
conventional scaffold systems. The ring, collar, rosette or
component with similar functionality, is referred to as a rosette
with respect to the invention; the vertical standard or component
with similar functionality, is referred to as a vertical member
with respect to the invention and the ledger, guardrail or
component with similar functionality is referred to as a horizontal
member. The use of the foregoing terms is not to be interpreted as
limiting the scope of the invention.
[0012] As noted herein, components of the invention include at
least one horizontal member, preferably having an internal wedge
head at each end thereof, at least one vertical member including at
least one rosette positioned thereon in coaxial alignment with the
vertical member, the rosette having apertures for receiving mating
elements, or prongs, of an internal wedge head, an internal wedge
assembly within the horizontal member, the internal wedge assembly
having a first rod with a wedge portion at a first end thereof, the
first rod being coupled at a second end thereof to an internal
crank/cam assembly, an external handle coupled to a crank axle of
the internal crank/cam assembly, the internal wedge assembly
further having a second rod with a wedge portion at a first end
thereof, the second rod being coupled at a second end thereof to
the internal crank/cam assembly, each of the internal wedge heads
having at least one or a plurality of mating elements or prongs
dimensioned to fit within a grid of apertures formed in the
rosette, the internal wedge head having a bore through which the
wedge portion wholly or partially extends to lock the internal
wedge head, and hence, the horizontal member to the rosette and
wholly or partially retracts to unlock the internal wedge head, and
hence, the horizontal member from the rosette.
[0013] To those skilled in the art to which this invention relates,
many changes in construction and widely differing embodiments and
applications of the invention will suggest themselves without
departing from the scope of the invention as defined herein and in
the appended claims. The disclosures and the descriptions herein
are purely illustrative and are not intended to be in any sense
limiting.
DESCRIPTION OF THE DRAWINGS
[0014] A more complete understanding of the invention may be
obtained by reference to the following Detailed Description, when
taken in conjunction with the accompanying Drawings, wherein:
[0015] FIG. 1 illustrates a scaffold structure;
[0016] FIG. 2 illustrates a vertical standard;
[0017] FIG. 3 illustrates a conventional ledger with unsecured
wedges;
[0018] FIG. 4 illustrates the installation of an unsecured wedge
into a conventional ledger head;
[0019] FIG. 5 illustrates a rosette and conventional head and
wedge;
[0020] FIG. 6 is one embodiment of a rosette of the invention;
[0021] FIG. 7 is one embodiment of a vertical member of the
invention;
[0022] FIG. 8 is one embodiment of a horizontal member and internal
wedge head of the invention;
[0023] FIG. 9 is a cutaway view of a horizontal member and internal
wedge head showing an embodiment of the wedge assembly and
crank/cam assembly of the invention;
[0024] FIG. 10 is a cutaway view of a horizontal member and
internal wedge head showing an embodiment of the wedge assembly and
an alternative embodiment of a crank/cam assembly of the
invention;
[0025] FIG. 11 is a bottom, cutaway view of a pair of horizontal
members and corresponding internal wedge heads showing an
embodiment of the wedge assembly and crank/cam assembly of the
invention;
[0026] FIG. 12A is a view of the back end of an internal wedge head
showing the wedge bore and FIG. 12B is a top view of an internal
wedge head;
[0027] FIG. 13 is a perspective, cutaway view of a horizontal
member and internal wedge head showing an embodiment of the wedge
assembly and crank/cam assembly of the invention;
[0028] FIG. 14 is a side view of the horizontal member, internal
wedge head and rosette of the invention;
[0029] FIG. 15 is a perspective view of a rosette coupled to a
portion of a vertical member with an internal wedge head of the
invention and a conventional head/wedge coupled to the rosette;
[0030] FIG. 16 is a perspective view of two internal wedge heads of
the invention coupled at an angle to each other on a rosette;
[0031] FIG. 17 is a bottom perspective view of two internal wedge
heads of the invention coupled at a 90 degree angle to each other
on a rosette;
[0032] FIG. 18 is a perspective view of a cubic arrangement of the
scaffold of the invention;
[0033] FIG. 19 is a close-up view of the corners of the cubic
arrangement of FIG. 18; and
[0034] FIG. 20 is a second embodiment of an internal wedge head and
rosette arrangement of the invention.
DETAILED DESCRIPTION
[0035] The invention comprises a modular scaffold system that
overcomes the safety, rigidity, and labor issues inherent in
conventional scaffold systems. The ring, collar, rosette or
component with similar functionality, is referred to as a rosette
with respect to the invention; the vertical standard or component
with similar functionality, is referred to as a vertical member
with respect to the invention and the ledger, guardrail or
component with similar functionality is referred to as a horizontal
member. The use of the foregoing terms is not to be interpreted as
limiting the scope of the invention.
[0036] As noted herein, components of the invention include at
least one horizontal member which horizontal member preferably has
an internal wedge head at each end thereof, at least one vertical
member including at least one rosette affixed in coaxial alignment
thereon, the rosette having apertures for receiving mating elements
or prongs of an internal wedge head (which may be a separate
component of the horizontal member, or an integrated portion at the
end of the horizontal member), an internal wedge assembly within
the horizontal member, the internal wedge assembly having a first
rod with a wedge portion at a first end thereof, the first rod
being coupled at a second end thereof to an internal crank/cam
assembly, an external handle coupled to a crank axle of the
internal crank/cam assembly, the internal wedge assembly further
having a second rod with a wedge portion at a first end thereof,
the second rod being coupled at a second end thereof to the
internal crank/cam assembly, each of the internal wedge heads
having a plurality of prongs dimensioned to fit within a grid of
apertures formed in the rosette, the internal wedge head having a
bore through which the wedge portion extends wholly or partially
out of the internal wedge head to lock the internal wedge head, and
hence, the horizontal member to the rosette
[0037] An aspect of the invention is a joint for use in coupling a
horizontal member to a vertical member, comprising a rosette having
a set of radially arranged cut-outs, a horizontal member further
comprising a hollow tube having contained therein an internal wedge
assembly, the internal wedge assembly having a wedge portion at the
end thereof which is wholly or partially extendable and retractable
into the hollow tube of an internal wedge head and/or horizontal
member, the internal wedge head, or an end of the horizontal
member, having mating elements corresponding to the radially
arranged cut-outs of the rosette, wherein, when the mating elements
of internal wedge head or the horizontal member are received in the
radially arranged cut-outs of the rosette, the internal wedge
assembly, when actuated, causes the wedge portion to rigidly join
the internal wedge head or horizontal member to the rosette.
[0038] Referring now to FIG. 6, the top view of one embodiment of a
rosette 600 of the invention is shown. An embodiment of rosette 600
is circular in shape and has a breadth or extent. Such breadth or
extent may be any measure appropriate to allow the internal wedge
head to engage the rosette 600 as more fully described herein.
Rosette 600 has a central aperture 601 or cut-out in a
substantially circular shape dimensioned to receive the vertical
tubing of the vertical member. In another aspect, such central
aperture or cut-out may be any shape that corresponds to the
cross-sectional shape of a vertical member. Once placed on the
vertical tubing, rosette 600 can thus be welded or otherwise
attached in a co-axial alignment with the vertical tubing of the
vertical member. A plurality of rosettes can thus positioned and
affixed along the length of the vertical tubing. Between the outer
circumference of rosette 600 and the outer circumference of the
central aperture 601 are a plurality of radially arranged cut-outs
602 for receiving prongs of at least one internal wedge head as
further described herein. The grid arrangement of the radially
arranged cut-outs 602 allow for the flexible arrangement of
horizontal members to the vertical member via rosette 600. As seen
in FIG. 6, eight (8) radially arranged cut-outs are shown, although
a different number of radially arranged cut-outs can be arranged on
rosette 600. In an embodiment of the invention, the radially
arranged cut-outs 602 generally comprise trapezoids with inner and
outer edges having circular arcs of concentric circles of different
radii. The intersections of the line segments and arcs can be
filleted, comprising a concave easing of the interior corners to
reduce stress concentration. On a portion of, and further cut out
from, the inner and outer edges of such trapezoids are arc shaped
notches comprising a portion of a circle centered on the trapezoid.
The edges of intersection of each of the upper and lower surfaces
of the rosette with the vertical, interior walls of the rosette can
be rounded, beveled or chamfered. The radially arranged cut-outs
602 are dimensioned to receive the descending, vertical prongs of
the internal wedge head.
[0039] FIG. 7 is one embodiment of a vertical member 700 of the
invention having a plurality of rosettes 600 positioned and affixed
in coaxial alignment on vertical tubing 701.
[0040] FIG. 8 is one embodiment of a horizontal member 800 and
internal wedge head 801 of the invention wherein the internal wedge
head 801 is coupled to the first end of horizontal member 800.
Internal wedge head 801 further comprises a plurality of surfaces
and edges forming a polyhedron including extensions or prongs. One
aspect of internal wedge head 801 has main body 802 with a top
surface, bottom surface, left surface, front surface, right surface
and back surface, with edges corresponding to the plurality of
surface. The planes of main body 802 left surface and right surface
can be parallel to each other or angled with respect to each other.
The planes of main body 802 top surface and bottom surface are
substantially parallel to each other. Alternative shapes and
dimensions of the internal wedge head are within the scope of this
invention.
[0041] A horizontal upper extension 803 extends from a top portion
of the front surface of main body 802, the horizontal upper
extension 803 having a respective top surface, bottom surface and
left and right surfaces, a plurality of descending vertical prongs
804 (shown here as a pair of descending vertical prongs) descending
from the bottom surface of the horizontal upper extension 803. In
an embodiment of the invention, each vertical prong 802 extends
between 1/4 and 2/3 of the length from the edge joining the top
surface and the front surface of main body 802 to the edge joining
the bottom surface and the front surface of main body 802. A gap
exists between a pair of vertical prongs 804 dimensioned so as to
receive a portion of the rosette 600 between adjacent radially
arranged cut-outs 602. The planes of horizontal upper extension 803
left surface and right surface can be parallel to each other or
angled with respect to each other. The planes of horizontal upper
extension 803 top surface and bottom surface are substantially
parallel to each other. Alternative shapes and dimensions of the
horizontal upper extension and prongs are within the scope of this
invention.
[0042] Further extending from a bottom portion of the front surface
of main body 802 is a lower jaw 805 having a left surface, front
surface, right surface, top surface and bottom surface. The planes
of lower jaw 805 left surface and right surface can be parallel to
each other or angled with respect to each other. The planes of
lower jaw 805 top surface and bottom surface are substantially
parallel to each other. Alternative shapes and dimensions of the
lower jaw are within the scope of this invention.
[0043] On the front surface of main body 802, located between
horizontal upper extension 803 and lower jaw 805 is a bore opening
corresponding to bore 806 which extends through the main body 802
from the back surface thereof to the front surface thereof. Bore
806 receives wedge portion of a wedge assembly as further described
herein. Horizontal member 800 is fixedly coupled at a coupling
joint proximate the back surface of main body 802.
[0044] FIG. 9 is a cutaway view of horizontal member 800 and
internal wedge head 801 showing an embodiment of the internal wedge
assembly including the crank/cam assembly 910 of the invention. The
horizontal member 800 is a hollow tube, preferably cylindrical in
shape, having a first end and a second end. At the first end is
internal wedge head 801 and a second internal wedge head (not
shown) is also positioned at the second end. Within the horizontal
member 800 of the invention is an internal wedge assembly. The
wedge assembly has a first rod section 901 having a wedge portion
902 at the first end thereof 904 and a second rod section 903
having a corresponding wedge portion at the first end thereof (not
shown). The crank/cam assembly 910 is located between the second
end 905 of the first rod 901 and the second end 906 of the second
rod 903. The first rod section 901 and second rod section 903 are
preferably made of an alloy such as steel, iron or other resilient
material and can be treated by a process, including galvanization
or power coating.
[0045] The first rod section 901 and second rod section 903 can be
equal in length, but are preferably unequal in length so that the
handle of the crank/cam assembly 910 is offset, being closer toward
one end of the horizontal member 800 as opposed to the other end.
The second end 905 of the first rod section 901 and the second end
906 of the second rod section 903 each have a coupling means such
as a rotating joint, for rotatably coupling the ends of the rods to
end segments of a crank arm 909 of crank/cam assembly 910. Such
coupling means includes a rotating joint formed by an aperture
formed through the ends of each rod and corresponding aperture 911
in the crank arm 909 of the crank/cam assembly 910, the apertures
dimensioned for receiving a coupler component, such as a bolt and a
nut, a revolute, a pin, a rivet or the like. The coupler component
may include washers, bushings, bearings or similar components so as
to reduce the friction between the ends of the rod sections and the
crank arm 909. Further, locking or latching mechanisms may also be
incorporated into the crank/cam assembly so as to lock the
crank/cam assembly and corresponding coupled components in a
desired position.
[0046] Each such coupling means provides a rotation axis for each
of the rods with respect to the crank arm 909. The second end of
each rod can be directly coupled to the crank arm 909 or indirectly
coupled having interposed thereinbetween an intermediate component
made of a different material such as a different type of metal or
plastic having a joining means, such as an hollowed cylindrical
portion for receiving the second end of the rod and a revolution
means, such as an aperture and bolt and nut, revolute, pin or rivet
and associated washers, bushings and/or bearings for rotatably
coupling the interposed component to the crank/cam arm. In the
above described manner, the coupler components indirectly couple
the second end 905 of the first rod 901 and the second end 906 of
the second rod 903 together via the crank arm 909 of the crank/cam
assembly 910 to a handle.
[0047] The crank/cam assembly 910 which is positioned within the
tubing of horizontal member 800 comprises a rotatable crank axle
908, the ends of which are rotatably coupled to through the
interior sides of horizontal member 800, which rotatable crank/cam
axle 908 can be a cylindrical bolt, rivet, revolute or pin with
associated washers, bushings and/or bearings, an end thereof
extending out of horizontal member 800 orthogonally to the length
of the horizontal member 800 so as to receive a handle (not shown)
that responsively rotates the crank/cam axle 908 when actuated. In
this manner, crank/cam axle 908 provides a rotation axis for the
crank/cam arm 909.
[0048] Crank/cam arm 909 is rigidly coupled to crank/cam axle 908,
the arm segments of crank/cam arm 909 extending outwardly from the
central axis of crank/cam axle 908. Rotatably coupled to a first
extended segment of crank/cam arm 909 is second end 905 of the
first rod 901 and rotatably coupled to the second extended segment
of crank/cam arm 909 is the second end 906 of the second rod 903.
In this manner, when actuated, the rotational motion of the
crank/cam axle 908 is translated, via the crank/cam arm 909 into
substantially linear motion of the first end 904 of first rod 901
and first end (not shown) of second rod 903. Hence, when the handle
is turned in a first direction (actuated), it simultaneously causes
the wedge portion 902 of the first rod 901 and wedge portion of the
second rod (not shown) to each wholly or partially extend out of
the first end and second end, respectively of the horizontal member
800. When the handle is turned in an opposite direction (actuated),
it simultaneously causes the wedge portion 902 of the first rod 901
and wedge portion of the second rod (not shown) to wholly or
partially retract into the first end and second end, respectively
of the horizontal member 800.
[0049] At the end of each horizontal member 800 is an internal
wedge head 801 having a bore 806 through which the wedge portion
902 extends so as to engage under the lower planar surface of
rosette 600 when the prongs 804 are received through the top of the
rosette 600 in certain of the radially arranged cut-outs 602. In
addition to preventing the horizontal member from being uplifted
from the rosette 600, the wedge may also provide a frictional force
against the rosette 600 to hold the horizontal member rigid with
respect to the vertical member.
[0050] Crank/cam arm 909 can comprise a single arm having a first
segment and a second segment which is offset 180 degrees from the
first segment or, as seen in FIG. 11 or can comprise a pair of
parallel, apositioned arms, each having a first segment and a
second segment. Between the faces of the first segments of such
pair of arms, toward the distal ends thereof, is positioned the
second end of the first rod. Between the second segments of the
pair of apositioned arms, toward the distal ends thereof, is
positioned the second end of the second rod. Each of the second
ends are rotatably coupled to their respective segments at a
rotating joint comprising apertures through which a coupling
component such as a bolt and nut, revolute, pin, rivet and
associated washers, bushings and/or bearings and the like is
inserted.
[0051] Although an embodiment of a crank mechanism is shown in FIG.
9, a cam, slider/slot, plunger, spring loaded or other similar
mechanism can also be used in the internal wedge assembly to cause
the extension of the internal wedge through the internal wedge head
so as to lock the horizontal member into position with respect to
the vertical members via the rosette. For example, a cam mechanism
can be used to cause the extension of the first rod and second rod,
the second ends of such rods being biased against the cam using a
spring mechanism.
[0052] FIG. 10 is a cutaway view of a horizontal member and
internal wedge head showing an embodiment of the wedge assembly and
an alternative embodiment of a crank/cam assembly of the invention.
As seen therein, crank/cam arm 909 is replaced with a crank/cam
disk 1001 which is fixedly coupled to crank/cam axle 908. The
central axis of the crank/cam axle 908 intersects the center of the
crank/cam disk 1001. Rotatably coupled using a rotating joint in a
first aperture 1002 in crank/cam disk 1001 is second end 905 of the
first rod 901 and rotatably coupled using a rotating joint in a
second aperture 1003 in crank/cam disk 1001 is the second end 906
of the second rod 903. In this manner, the rotational motion of the
crank/cam axle 908 is translated, via the crank/cam disk 1001 into
substantially linear motion of the first end 904 of first rod 901
and first end (not shown) of second rod 903. In this manner, when a
handle rigidly coupled to the crank/cam axle 908 is turned in a
first direction, it simultaneously causes the wedge portion 902 of
the first rod 901 and wedge portion of the second rod (not shown)
to each wholly or partially extend out of the first end and second
end, respectively of the internal wedge head or horizontal member
800. When the handle is turned in an opposite direction, it
simultaneously causes the wedge portion 902 of the first rod 901
and wedge portion of the second rod (not shown) to wholly or
partially retract into the first end and second end, respectively
of the internal wedge head or horizontal member 800.
[0053] FIG. 11 is a bottom, cutaway view of a pair of horizontal
members 1101, 1111 with corresponding internal wedge heads 1102,
1112 on a rosette 600 showing an embodiment of the wedge assembly
and crank/cam assembly of the invention. As seen therein, the
crank/cam assembly 1104, 1114 comprise a pair of parallel,
apositioned arms, each having a first segment and a second segment.
Between the apositioned faces of the first segments of such pair of
parallel arms, toward the distal ends thereof, is positioned the
second ends of the first rods 1106A, 1116A. Between the apositioned
faces of the second segments of the pair of parallel arms, toward
the distal ends thereof, is positioned the second ends of the
second rods 1106B, 1116B. Each of the second ends are rotatably
coupled to their respective segments at a rotating joint comprising
apertures through which a coupling component such as a bolt and
nut, revolute, pin, rivet and associated washers, bushings and/or
bearings and the like are used. The crank/cam arms seen in
crank/cam assembly 1104, 1114 are rigidly coupled to a respective
crank/cam axle, the arm segments of such crank/cam arms extending
outwardly from the central axis of crank/cam axle. Each handle
1108, 1118 is fixedly coupled on the outside of horizontal member
1101, 1111 to a respective crank/cam axle of a crank/cam assembly
1104, 114, In this manner, the rotational motion of the handle
1108, 1118 rotates crank/cam axle, which rotation is translated,
via the crank/cam arms into substantially linear motion of the
first end of first rod 1106A, 1116A and first end (not shown) of
second rod 1106B, 1116B. Hence, when the handle 1108, 1118 is
turned in a first direction, it simultaneously causes the wedge
portion 1107, 1117 of the first rod 1106A, 1116A and wedge portion
(not shown) of the second rod 1106B, 1116B to each wholly or
partially extend out of the first end and second end, respectively
of the horizontal member 1101, 1111 and through the bore 1103, 1113
of internal wedge head 1102, 1112. When the handle 1108, 1118 is
turned in an opposite direction, it simultaneously causes the wedge
portion 1107, 1117 of the first rod 1106A, 1116A and wedge portion
(not shown) of the second rod 1106B, 1116B to wholly or partially
retract into the first end and second end, respectively of the
internal wedge head 1102, 1112 positioned at the end of the
respective horizontal member 1101, 1111.
[0054] FIG. 12A is a view of the back end of an internal wedge head
801 showing the wedge bore 806 through which a wedge portion (not
shown) extends from the tubing of a horizontal member so as to lock
the horizontal member into position with respect to the vertical
member via the rosette. FIG. 12B is a top view of internal wedge
head 801 showing a cylindrical extension 1201 that is dimensioned
to fit within the interior wall of a hollow horizontal member. The
internal wedge head 801 can then be bolted, welded, clamped or
otherwise affixed to a horizontal member.
[0055] FIG. 13 is a perspective, cutaway view of a horizontal
member 1101 and internal wedge head 1102 of FIG. 11 showing an
embodiment of the wedge assembly and crank/cam assembly 1104 having
handle 1108 which is responsively coupled, via a crank/cam axle and
crank/cam arms to rod 1106A of the invention. As seen therein,
horizontal member 1101 is coupled to vertical member 1301 via
rosette 600, internal wedge head and the internal wedge
assembly.
[0056] FIG. 14 is a side view of the horizontal member 800 coupled
to internal wedge head 801, which is coupled to rosette 600 of the
invention. FIG. 15 is a perspective view of a rosette 600 coupled
to a portion of a vertical member 1500 with an internal wedge head
801 of the invention and a conventional head/wedge 1501 coupled to
the rosette 600. FIG. 16 is a perspective view of two internal
wedge heads 801A, 801B of the invention coupled at an angle to each
other on a rosette 600 which is fixedly attached to vertical tubing
1601 of a vertical member. FIG. 17 is a bottom perspective view of
two internal wedge heads 801A, 801B wherein descending prongs 804A,
804B are received in respective radially arranged cut-outs 602 of
rosette 600. Rosette 600 is fixedly attached, via welding or
similar process, to vertical tubing 701 of the vertical member. The
selection of the radially arranged cut-outs 602 in which to place
prongs 804A, 804B as seen in FIG. 17 serve to position the
horizontal members at a 90 degree angle with respect to each other.
As seen therein, both extensions of the pair of prongs are located
within a single radially arranged cut out. However, the gap between
pairs of prongs is dimensioned to fit over the spoke between two
adjacent pair of radially arranged cut-outs as seen with internal
wedge head 1102 in FIG. 11. In this manner, up to 13 different
angles can be obtained between a pair of horizontal members on a
rosette having eight (8) radially arranged cut-outs (each internal
wedge head possible in any one of sixteen (16) positions).
Furthermore, using a rosette having eight (8) radially arranged
cut-outs, up to eight (8) horizontal members can be placed on the
shown rosette. Because the handle coupled to the crank/cam assembly
is located toward one end of each horizontal member, a single
installer can install and lock into place up to eight ends (8) of
eight (8) horizontal members into a single vertical member
substantially without changing the installer's position.
[0057] FIG. 18 is a perspective view of a cubic arrangement of the
scaffold 1800 of the invention showing eight horizontal members
each having a first internal wedge head on a first end and a second
internal wedge head on a second end, four vertical members (1 back
vertical member hidden), each vertical member having fixedly
attached thereon in coaxial alignment a first rosette and a second
rosette, each internal wedge head being coupled to a rosette. FIG.
19 is a close-up view of the corners of the cubic arrangement of
FIG. 18 showing six horizontal members 1902A-F, having internal
wedge heads on the ends thereof 1903A-F, two vertical members
1901A-B, each vertical member having fixedly attached thereon at
least one rosette 1904A-B, each shown internal wedge head being
coupled to a rosette.
[0058] FIG. 20 is a second, alternative embodiment of an internal
wedge head 2002 and rosette 2001 arrangement of the invention,
wherein the internal wedge head includes four (4) descending prongs
dimensioned to fit within either two (2) or four (4) corresponding
radially arranged cut-outs of rosette 2001. The rosette 2001 of
this embodiment thus has 16 radially arranged cut-outs. Rosette
2001 is fixedly coupled to vertical member 2003 and internal wedge
head 2002 has a wedge bore through which wedge portion 2006 wholly
or partially extends. Wedge portion 2006 is attached or integrated
with a wedge assembly that includes a crank/cam assembly internal
to a horizontal member as described herein.
[0059] The invention has at least one rosette attached, e.g.,
welded, to each vertical member, and a vertical member may have a
plurality of evenly or unevenly spaced rosettes affixed, e.g., by
weld, along a vertical member. The rosette has a pattern or grid of
apertures designed to receive the mating elements, such as prongs
at the end of a horizontal member. An internal wedge head may be
located at the end of the horizontal member. The horizontal member
is a hollow tube, preferably cylindrical in shape, having a first
end and a second end. At the first end and the second end may be
fixedly attached, an internal wedge head, as more fully described
herein. Within the horizontal member of the invention is a wedge
assembly.
[0060] The wedge assembly has a first rod section having a wedge
portion at the first end thereof and a second rod section having a
wedge portion at the first end thereof. The first rod section and
second rod section are preferably made of steel, iron or other
resilient material and can be treated by a process. The first rod
section and second rod section can be equal, but they are
preferably unequal in length. The second end of the first rod
section and the second end of the second rod section each have an
aperture there-through for receiving a coupler, such as a bolt and
a nut, rivet, revolute, pin and associated washers, bushings and/or
bearings, each coupler being coupled to a crank/cam assembly that
is located between the first rod and the second rod. The couplers
rotatably couple the second end of the first rod and the second end
of the second rod together via the crank/cam assembly and one of
the couplers, e.g., a bolt, extends out of the horizontal member
orthogonally to the length of the horizontal member so as to
receive a handle that responsively rotates the crank/cam axle and
hence the first rod and the second rod. In this manner, the
rotational motion of the crank/cam axle is translated to linear
motion of the first rod and second rod. More specifically, the
handle, when turned in a first direction, causes the wedge portion
of the first rod and wedge portion of the second rod to wholly or
partially extend out of the first end and second end, respectively
from the internal wedge head and/or horizontal member. When the
handle is turned in an opposite direction, it causes the wedge
portion of the first rod and wedge portion of the second rod to
wholly or partially retract into the first end and second end,
respectively of the internal wedge head and/or horizontal
member.
[0061] In an embodiment, at the end of each end of the horizontal
member is an internal wedge head that may be a fixedly coupled
separate component of the horizontal member or a single integrated
part of the horizontal member. The internal wedge head has a bore
there-through to receive the wedge portion of the respective rod.
The internal wedge head further has a plurality of vertically
descending prongs extending from the bottom facing surface of an
extension thereof, the prongs of which are dimensioned to be
positioned within the grid pattern of the rosette. When the
internal wedge head is placed on the rosette, the face from which
the prongs extend rests on portions of the rosette and the prongs
extend through the grid apertures. On a face of the head orthogonal
to the face on which the prongs extend, a wedge bore is provided to
allow the wedge portion of a rod to be extended when the handle is
turned, locking the internal wedge head, which is coupled to the
horizontal member, to the rosette, which is coupled to the vertical
member. Frictional force may be exerted between the wedge portion
and a planar surface of the rosette to lock the position of the
horizontal member to that of the vertical member.
[0062] Note that because the wedges of the invention are positioned
within the hollow horizontal member and the prongs are integrated
into the internal wedge head, which is fixedly coupled or
integrated with the horizontal member, the scaffold of the
invention remains rigid during construction and thereafter, and the
risk of falling wedges or collapsing scaffolds is significantly
reduced, if not eliminated.
[0063] In an embodiment of the invention, the design of the
internal wedge head at each end of each horizontal member keeps
scaffold components square and ridged at all times utilizing
predetermined angles via the grid design. The scaffold design of
the invention reduces leading edge fall hazards associated with
conventional scaffold systems. The scaffold design of the invention
also reduces the need for hand tools during the installation and
dismantling of horizontal members. Advantageously, the scaffold
design of the invention reduces the amount of labor and time needed
to install and dismantle a scaffold system.
[0064] The invention components can be fabricated from a variety of
materials, including galvanized or powder coated steel, iron or
other resilient material. The rosette preferably has a seven inch
(7'') diameter, and the internal first and second rods can comprise
two square, or cylindrical rods, made of e.g., steel or iron, each
having a wedge shaped wedge portion added or integrated at an end,
the opposite ends being coupled to the crank/cam assembly. The
wedge portion preferably comprises a piece of hard material with
two principal faces meeting in a sharply acute angle. The wedge
portions lock the horizontal members into the vertical members via
the rosette creating a joint. The two (2) internal rods are each
coupled at a revolution joint. An embodiment of each revolution
joint comprises two (2) washers and two (2) bolts. The rods are
bolted together using a crank/cam assembly. The rods thus oscillate
internally of the tube and lock under the rosette, thus locking the
horizontal member preventing uplift. In this manner, the ends of
the horizontal member lock into the vertical member. Using the grid
pattern of apertures on the rosette and head having prongs
dimensioned to fit therein, various angles between the horizontal
members can be obtained (e.g., 45, 90, 180 degrees) for the
elevated working platform.
[0065] Advantageously, the invention allows the erector to engage
and disengage both internal wedge portions of a single horizontal
member from a single point reducing installation time and creating
a safer work environment. This is because the single handle between
the first end and the second end of the horizontal member engages
and disengages each wedge substantially simultaneously. In this
manner, up to eight (8) horizontal members can be attached to a
single vertical member by a single installer without changing his
position.
[0066] The invention further comprises a grid of components that
mesh together creating rigid angled connection among a plurality of
horizontal members at a vertical member. Both of the wedges which
are part of an internal wedge assembly, are locked into position at
the rosette on a vertical member from a single position. The
internal wedge portions are locked into place by an external handle
eliminating the use of any hand tools. The external handle can also
be locked into place creating a secondary locking device.
[0067] The embodiments shown and described above are only
exemplary. Even though numerous characteristics and advantages of
embodiments of the invention have been set forth in the foregoing
description together with details of the invention, the disclosure
is illustrative only and changes may be made within the principles
of the invention to the full extent indicated by the broad general
meaning of the terms used herein. For example, the concepts
described herein for coupling horizontal members to vertical
members can be used to couple bracing members to vertical members
or to horizontal members. Coupling includes, but is not limited to
attaching, engaging, mounting, clamping, welding, bolting and
components used for coupling include bolts and nuts, rivets,
clevis, latches, clamps, welds, screws, rivets and the like.
Further, a rosette having eight (8) radially arranged cut-outs is
described herein for illustrative purposes and a rosette having
more or less radially arranged cut-outs is considered to be within
the scope of this invention. Also, the invention describes a
rosette having a standard diameter of about seven (7) inches,
however, any suitable diameter can be used. The use of an internal
wedge head with a pair, or an internal wedge head with two pair, of
descending vertical prongs is described herein for illustrative
purposes and an internal wedge head having one or more descending
prongs is considered within the scope of this invention. The
rosette can include any suitable cut-out shape that is dimensioned
to receive a corresponding prong or set of prongs of an internal
wedge head. The vertical member can have any number of coaxially
aligned rosettes attached thereto, the vertical spacing of such
rosettes being any such distance as is suitable for the intended
use. More generally, the invention is a scaffold system with a
horizontal member, a vertical member at least one rosette affixed
in coaxial alignment to the vertical member and an internal wedge
assembly within the a horizontal member, portions of the internal
wedge assembly for locking the horizontal member to the rosette.
The vertical member has a plurality of evenly spaced rosettes
affixed in coaxial alignment along the vertical member and at least
one rosette has a pattern or grid of apertures designed to receive
the end of the horizontal member. The scaffold system can also have
a wedge head coupled to one end of the horizontal member and a
handle coupled to the internal wedge assembly. Each wedge head has
prongs extending therefrom, the prongs dimensioned to fit within
the grid of apertures of the rosette. The internal wedge assembly
can include a linkage, the handle being responsively coupled to a
first portion of a linkage of the internal wedge assembly and the
wedge being coupled to a second portion of the linkage; and a rod,
the first end thereof coupled at a third portion of the linkage,
the second end of the rod coupled to a second wedge for extension
and retraction at the distal end of the horizontal member. The
internal wedge assembly can further comprise a linkage mechanism.
with the internal wedge assembly having a first rod section having
a wedge portion at the first end thereof and a second rod section
having a wedge portion at the first end thereof, wherein the second
end of the first rod section and the second end of the second rod
section are each rotatably coupled to the linkage mechanism. The
first rod section and second rod section can be unequal in length.
In addition to rods, cables and similar components for transferring
motion can be used to transfer the motion of the handle to the
extension and retraction of the wedges. The internal wedge assembly
can further use a crank/cam assembly, the crank/cam assembly having
a first rod section with a wedge portion at the first end thereof
and a second rod section with a wedge portion at the first end
thereof, wherein the second end of the first rod section and the
second end of the second rod section are each rotatably coupled to
the crank/cam assembly. The handle is then coupled to the crank/cam
assembly, which, when actuated causes the wedge portion of the
first rod and wedge portion of the second rod to partially or
wholly extend or retract out of the first end and second end,
respectively from the horizontal member, depending on the direction
that the handle is turned. The first rod section and the second end
of the second rod section can, in an aspect of the invention, each
have an aperture there-through each for receiving a coupler forming
a rotation joint, each coupler being coupled to a crank/cam
assembly positioned between the second end of the first rod and the
second end of the second rod. The external handle can be coupled to
the crank/cam assembly, wherein when the handle is turned, causes
the wedge portion of the first rod and wedge portion of the second
rod to wholly or partially extend or retract out of the first end
and second end, respectively from the horizontal member.
* * * * *