Cross-Reference to Related Application

This application claims the priority benefit of U.S. Provisional Application 62/490,908 filed April 27, 2017, which is incorporated by reference herein in its entirety.

Background

A scaffold frame is an interconnected series of horizontal vertical scaffold members and vertical scaffold members used to create a supporting structure for an elevated work surface. The horizontal and vertical scaffold members are generally pipe shaped members (circular or square in cross section, for instance) where the ends of each horizontal scaffold member terminates in connectors that attaches to a vertical scaffold members. The connectors can be clamp members (such as in tube and clamp scaffolding, see for instance, Figure 1) or more complex connectors, such scaffolding where an end connector positioned on the end of a horizontal member, where the end connector has a lip or hook section that couples with a structure on a vertical scaffold member. The lip sections are designed to engage or rest on the corresponding vertical joint connector, such as an upstanding cup or an annular ring positioned on a vertical scaffold member. One such joint is disclosed in U.S. patent number 4,445,307, which discloses a connector positioned on a horizontal scaffold member, where the connector has two vertically spaced hook sections.

Another cup type of latching connector is disclosed in U.S. patent numbers 5,078,532 and 5,028, 164 and in U.S. application number 12/489, 166 all hereby incorporated by reference. These patents also show an end connector positioned on a horizontal scaffold member, where the connector has two vertically spaced hooked sections that couple with two vertically spaced upstanding cup or ring members located on the vertical scaffold member. In this device, the hooked sections engage the top edge of the cup, and a pivoting member or latch, positioned on the horizontal end connector, is pivoted into position below the cup member.

Instead of upstanding cups, a flat annular ring with openings in the ring may be used as the vertical connector on the vertical scaffold member, to couple to a connector on a horizontal scaffold member. Examples of annular ring/connector systems are shown in U.S. patent numbers 4,273,463; 6,027,276; 5,961,240; 5,605,204; 4,840,513; all of which are hereby incorporated by reference. These systems are generally referred to as wedge or pinlock scaffold systems. The pinlock system relies upon a wedge or pin being slidable (generally hammer driven) through the horizontal end connector and rosette. The above "system" scaffolds require a horizontal member to couple to a vertical member, that is, a horizontal member cannot couple to another horizontal member.

Once a scaffold frame is erected, an elevated work surface is created by using scaffold boards that are supported at each end of the board by horizontal scaffold frame members. Typically, scaffold boards or planks are wooden, fiberglass, or metal board-like members, having a length (such as 10 feet) and a width, such as 9 inches. A scaffold board generally comprises a top surface, such as 6 inch, 9 inch, 12 inch, or 18 inch wide board, and come in various lengths, such as 2 feet long to 10 to 16 feet long. A typical metal scaffold board is shown in Figure 2, showing a metal plank 1, having a top surface 40, and two side rail extensions 70 extending downwardly at about 90 degrees to the top surface 1 adjacent the edges of the top surface. The top surface 40 can be a solid surface, a surface with drain holes, or formed from a series of metal plates (see Figure 3). The scaffold plank side rails 70 may be integrally formed with the top surface (such as by roll forming the plank from a single piece of metal), or may be separately attached, such as by welding, riveting, etc. Each metal board top surface has two terminating ends, (a first terminating end edge 202 and a second terminating end edge 204 (not shown)). The edge is linear, but may be curved. Also shown in Figure 2, the board 10 has a first top side edge 212 and a second top side edge 214. Located near each terminating end edge 204, 206 is at least one (preferably two or more) clip members 50. As shown in Figure 2, one embodiment of clip members 50 are shaped plate members with a downwardly facing channel 52 rearward of downward lip section 51. The channel 52 is shaped to engage a horizontal scaffold member in a channel 52 or cutout section (not shown). As shown, the clips are vertical orientated plate members, one attached to each side rail 70. The clips can be "L" shaped member, "U" or "C" or other "hook" type of engagement members. In the embodiment shown in Figure 2, each clip 50 has a leading downward facing lip portion 51 (forming a hook- like structure) and a downward facing channel 52 behind the lip, together forming a "U" shaped clip or cleat 50. The channel 52 is located between the lip 51 and the adjacent terminating edge 202 or 204 of the scaffold board. The channel 52 may end before the respective terminating end edge 202 or 204, or at the terminating end edge, or in other embodiments, behind the terminating end edge. When a scaffold board 10 is placed in a scaffold structure, the clip channel 52 will rest or engage a horizontal scaffold member, thereby supporting the scaffold plank 10. The clips 50 can be vertical orientated plates, such as shown in Figure 2, or the clip plates 50 may be substantially horizontally oriented formed or shaped plates, such as shown in Figure 4, or the clips may be square or circular or other shapes in cross section to couple with a horizontal scaffold member or another scaffold plank. The scaffold elevated work surface generally forms a continuous uninterrupted surface, with safety railing surrounding the work deck or work surface. Often however, the elevated surface may have to be constructed around a structure or obstacle. For instance, pipes, chimneys or conduits may need to extend through the work deck. An obstruction that penetrates through the deck of a scaffold deck will leave an opening in the deck, where the length of the opening corresponds to that of the adjacent scaffold board, as depicted in Figure 5, a top view of a deck with a conduit extending through the deck area. To close the resulting opening, often wooden scaffold boards are used across the opening, where the boards are placed across the metal planks (for instance, at 90 degrees to the metal planks). However, the wooden planks are a tripping hazard.

Alternatively, two "interior" horizontal scaffold members can be positioned in the interior of the frame, on opposite sides of the obstruction (which will require additional vertical members, as the horizontal members generally couple to a vertical scaffold member, particularly in system scaffolding). Note, however, the "additional vertical scaffold member" can be an intermediate scaffold joint, one embodiment of which is as disclosed in U.S. patent number 8,973,711, hereby incorporated by reference in its entirety, to create a frame structure to allow placement of short scaffold planks at right angles to the existing scaffold planks, to thereby close the opening created by the obstacle. This is depicted in Figure 6 and Figure 7. A better system is needed to accommodate openings in scaffold decks.

Brief Description of the Drawings

Figure 1 is a cartoon perspective of a scaffold system with elevated deck.

Figure 2 is a side perspective view of a prior art high profile scaffold board.

Figure 3 is top perspective view of another prior art high profile scaffold board.

Figure 4 is a top perspective view of one end of one embodiment of the improved low profile scaffold boards.

Figure 5 is a top view of a scaffold decking penetrated by an obstacle.

Figure 6 is a top view of a scaffold decking of figure 5 with intermediate horizontal scaffold members laid in the perimeter of the opening. Figure 7 is a top view of a scaffold decking of figure 6 with scaffold planks laid across and supported by the intermediate horizontal scaffold members.

Figure 8 is a top perspective view of one embodiment of an improved low profile scaffold board.

Figure 9A is a side elevation view of one end of the scaffold board of figure 8.

Figure 9B is a side elevation view of two scaffold boards as in figure 8 coupled together in a side-to-end configuration.

Figure 9C is a top elevation view of one end of the scaffold board of figure 8.

Figure 10 is a top perspective view of a cross section through the scaffold board of figure 8. Figure 11A is a top elevation view of another embodiment of the improved scaffold board.

Figure 11B is a side elevation view of the scaffold board of figure 11 A.

Figure 11C are side elevation views of different embodiments of low profile clips.

Figure 11D are end views of the scaffold board of figure 11 A, with l lD-1 showing an end view of the top portion, 11D-3 showing an end view of the bottom portion, and 11D-2 showing an end view of the assembled bottom and top portion.

Figure HE is a side elevation view of two of the scaffold boards of figure 11 coupled together in an end-to-side configuration.

Figure 12 is a perspective view depicting an embodiment of the improved boards in aside- to-end configuration around an obstacle.

Figure 13 is a top perspective view of a scaffold deck depicting joining a series of scaffold members (10-1 through 10-7) to two adjacent improved scaffold members (10-C and 10-D) in a side to end configuration.

Figure 14A is a top elevation view of another embodiment of the improved scaffold board (a high profile configuration).

Figure 14B is a side elevation view of the scaffold board of figure 14A.

Figure 14C are side elevation views of different embodiments of high profile clips.

Figure 14D are end views of the scaffold board of figure 14A, with 14D-1 showing an end view of the top portion, 14D-3 showing an end view of the bottom portion, and 14D-2 showing an end view of the assembled bottom and top portion.

Figure 14E is a side elevation view of two of the scaffold boards of figure 14 coupled together in an end-to-side configuration. Detailed Description of the Invention

The invention is an improved scaffold plank. As shown in the view of Figure 8, one embodiment of the plank is a board like member 10, having a first and second terminating ends 202, 204, first and second side edges 212, 214, a top surface 40 extending between the two terminating ends and two side rails 70, extending downwardly from the top surface at about 90 degrees, running substantially the length of the board 10, and are positioned on the scaffold board near the side edges 202 and 214. Positioned at or near terminating ends 202, 204 is at least one shaped clip 50, shaped to couple with a horizontal scaffold member. Generally, the clips are "L," "U" or "C" shaped plates extending outwardly from the terminating ends of the plank 10. As shown in Figure 8, the clips 50 are attached to an end brace 60 that extends between the side rails 70 of the plank 10. The clips 50 could also be attached to the top surface 40, or side rails 70, or be integrally formed with the top surface or rails. In the embodiment shown, the clips 50 are flat metal plates bent in a "U" shape, where the plate is orientated substantially horizontally (as opposed to orientated in a vertical orientation, such as shown in Figure 2). The horizontal orientation of the clip 50, where the top of plate above the channel 52 is approximately at the height of the top surface 40 of the plank, allows for the top surface 40 of the plank to closely align with the top surface of a supporting horizontal member, such as shown in Figure 9A. The top surface 40 shown is formed from a metal plate, such as 16 gauge steel, with drain holes there through.

As can be seen in Figure 8, in one embodiment, the clips 50 on opposite terminating ends are not aligned, but are offset to accommodate placement of scaffold boards "end-to- end" lengthwise on the same horizontal scaffold member. On each terminating end 202 and 204, one clip 50A is positioned near a side rail 70, while the other clip 50B is offset and interior to the board from the opposing side rail 70. Also shown is optional tab 90, which projects from the top surface of the board 40, and has a thickness of a clip. The tab 90 is placed near the inward clip 50B, to resist rotation of the board on the supporting horizontal scaffold member of supporting board member. Tab 90 is positioned so not to interfere or overlap with an adjacent scaffold board clip when placed end-to-end lengthwise or in an end- to side configuration shown in Figure 10.

As shown in the embodiment of Figure 8, side rails 70 are positioned adjacent the top surface 40 near the first and second top side edges 212, 214 to provide stiffening or a truss like component to the board 10. In one embodiment, shown in Figure 10, the side rails 70 are shaped frame members, shaped with a bottom facing foot 71. Each side rail 70 has at least one outward facing surface 75, and one inward facing surface 76. The side rails 70 can be integrally formed with the top surface 40, such as by roll forming, or the side rail 60 may be attached to the top of the plank 40, such as by welding or with rivets or other mechanical attachment means. The side rails 70 can be a more complex assembled structure having multiple "rails" or shaped metal pieces, with multiple inward facing surfaces 76 and multiple outward facing surfaces 75, such as shown in Figure 11. As shown in his cross section, the board is of two piece construction. The top 40 of the board 10 is formed with first downward side rails, 70A (Figure 11A). The bottom of the board, 43, is a second piece, formed with second upward side rails 70B (Figure 11B). The top and bottom are combined in the assembled board 10 (shown in Figure 11C), such as by welding the top piece to the bottom piece. As shown in Figure 8, the side rails 70 may also have openings 79 therethrough. The openings 79 reduce the weight of the board 10. If openings 79 are included in the side rails 70, preferably the openings 79 are suitably sized to allow for placement of a "slick tube" (a smooth tubular member lacking typical horizontal end connectors) through the openings, so that adjacent boards can be coupled with the slick tube, providing additional strength and stiffness to the decking formed from the scaffold boards.

The top surface 40 of the scaffold board 10 also has a series of openings or slots 100. In the embodiment shown in Figure 8, the slots 100 are placed near but offset from the top side edges of the board, generally with at least a portion of the slot 100 extending inwardly (or behind) at least outwardly facing surface 75 of the side rails. In the embodiment shown, the slots 100 are aligned parallel with the side rails 70. The slots 100 in this embodiment are located at a specific distance inward from the top edges of the board, and sufficiently sized to allow placement of a clip 50 of a second scaffold board, orientated at 90 degrees, through a slot 100, as shown in Figure 9B. In this configuration, two boards are coupled together in an "end-to-side" configuration, with the "end" of one board coupled to the "side" of a second board, allowing for two boards to be coupled to each other at about 90 degrees, without an intervening horizontal scaffold member. As shown in this figure, the slot 100 in this embodiment is orientated so that the lip 51 of the clip 50 of the second board extends through the slot, and the channel cut out of the second board is supported by the first scaffold board' s top surface 40. The slots 100 are configured to allow such board-to-board coupling, where the coupled boards are orientated at 90 degrees to one another with the top surface of the coupled boards being adjacent, but preferably not overlapping. As shown in Figure 12, one board 10B is coupled to an adjacent board 10A, at 90 degrees to board 10A, where the clips 50 on board 10B mate with slots 100 on board 10A. This board-to-board coupling does not require an intervening horizontal member (such as would otherwise be required, as shown in Figure 7).

As shown in Figure 13, a decking can be formed by coupling some board members to horizontal scaffold members (board 10-A, 10-B, 10-C and 10-D), while coupling other boards (10-1, 10-2, 10-3, 10-4, 10-5, 10-6 and 10-7) at 90 degrees to certain (boards 10-C and 10-D) of the boards supported by horizontal scaffold members. As shown in Figure 12, such board-to-board coupling allows for placement of a scaffold structure around obstructions, such as pipes 1000. In the embodiment shown in Figure 9B, the coupled board 10B top surface is slightly higher than the adjoining board 10A top surface. These surfaces can be aligned if the side edge of the board 10A, immediately adjacent the openings 100, are formed (such as by roll forming) to be slightly depressed from the top surface 40 of the board (depressed the thickness of the clip plate 50, for instance). The improved scaffold boards can be combined with existing scaffold boards, or used alone, to create scaffold decking. The placement of the clips 50 on the end edges of each board can be varied, and the number of clips can be varied. As shown, the slots 100 are uniformly distributed, but this also can be varied. For instance, a board may have one terminating end containing three clips spaced in the center of a board, while the other terminating end of the board has two clips located near opposing side rails. The openings or slots 100 in the plank do not have to be uniformly spaced, but are located and spaced to couple with the respective clips. In certain embodiments, slots 100 may also be present in the ends of the boards to accommodate end- to-end placement, such as shown in the embodiment shown in Figure 14, later described.

If the board is constructed with clips 50 positioned vertically on the side rails (such as shown in Figure 2), the desired openings or slots 100 in the top portion of the board may be slots that start at the board side edge, and extend from the edge inwardly toward the center of the board, such as shown in Figure 14 and ll)(Figure 14 shows a high profile board, while Figure 11 shows a low profile board). In these two embodiments, the clips on the high profile board are vertically oriented plates, while the clips on the low are also vertical plates but of thicker material, as the top of the clip above the channel is thinner, but must still be sufficiently strong to support the scaffold board. Instead of plates, the clips could also be formed from square or rectangular rods. As shown in this embodiment in Figures 14E and HE, the cleats or clips 50 on the board supported board 10A extend partially through the side rail 70 of the supporting board 10B, through the slide slits 100 on the supporting board. The slots 100 partially extend through the side rail 70, but generally, not completely through the side rail 70, as the side rail 70 (or a portion thereof) will support the coupled board, as depicted in Figures 14E and HE. The side rail, as shown, has an inverted or upside down "L" shape, (both sides therefore forming a "T" shaped board in cross section) where the leg of the L is positioned near the top surface of the board. The height of this top leg of the L should preferably closely match the height of a clip above the associated channel plus the thickness of the top surface. This height allows a side to end configuration to have the two adjoining top surfaces of the boards to be level or almost level with each other. The length of the top leg of the L should closely match the length of the channel of a clip from the inner edge of the downwardly projecting lip to the adjoining end edge of the associated board. This length allows two boards, in a "side to end configuration" to be positioned so that the side edge of the supporting board is almost immediately adjacent to the end edge of the supported board. That is, the two top surfaces of the boards will be adjacent, with only a small gap between the boards in a side to end configuration. Proper dimensioning allows a clip to rest on the side wall and allow the two top surfaces to be closely aligned. Using one or more pieces, such as the top and bottom pieces shown in Figures 14D and 15D, provides strength and rigidity to the side rail to assist to support a board on such side rails.

Details of these boards are shown in the remaining portions of Figures 14 and 11. For instance. As shown in Figure 14D, the board 10 is formed from a top piece 200 and a bottom piece 300. Both top and bottom pieces have side rail extension portions 70. On the top piece 100, the side rail extension 70 includes a ledge portion 77 where the side rail portion bends inwardly 80 degrees. The slots 100 in the top of the board extend through the top side rail portion, but preferably not through the bottom side rail portion. When a board supports another board in an end-to-side configuration, the side supported board's clips will extend through the slots in the supporting board, to terminate and rest (and be supported by) the ledger 77, as shown in Figure 14E.

When vertical clips are used, the two terminating ends of the scaffold board may be mirror images, or almost mirror images, as the offset needed for horizontal clips is not required for end-to-end positioning. See Figures 14A and HA. As shown, the terminating ends, 204 and 202 are also shown with slots 100. These terminating slots allow two boards, placed in an end-to end relationship (where both boards are supported by the same horizontal scaffold member), to have the adjoining top surfaces 40 located adjacent to each other with little or no gap between the adjoining boards (not shown).

To assemble boards in a side-to-end configuration in an existing scaffold frame structure, a first scaffold plank utilizing the slotted openings is positioned in a scaffold structure, supported on each of its terminating ends by opposing horizontal scaffold members. A second scaffold plank (which may lack the slotted openings 100, but has end clips 50) is positioned at 90 degrees to the first scaffold plank, with the clips at a first end of the second board positioned above corresponding slots 100 of the first scaffold board (i.e., those slots along the side edge of the first board). The second scaffold board is lowered, so that the clips at the first end of the second board partially pass through the aligned slots or openings in the first board, until the first end of the second scaffold board member is supported by the first scaffold board. One end of the second board is now coupled to, and supported by, the first board, without an intervening horizontal member between the first and second board members. The clips on the second end (the distal end) of the second board may be supported by a another horizontal scaffold member, or supported by a third scaffold board orientated 90 degrees to the second scaffold board, with the third scaffold board having slots that align with the clips at the second terminating end of the second scaffold board.

While the illustrative forms disclosed herein have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the disclosure. For instance, the improved board may have only a single side adapted with slots to support a board in a side to end configuration. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the example and descriptions set forth herein, but rather that the claims be construed as encompassing all the features of patentable novelty which reside herein, including all features which would be treated as equivalents thereof by those skilled in the art to which this disclosure pertains.

When numerical lower limits and numerical upper limits are listed herein, ranges from any lower limit to any upper limit are contemplated.