CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application claims the benefit of U.S. Provisional Patent Application No. 62/963,408, entitled LADDERS AND LADDER RUNGS, filed on January 20, 2020, the disclosure of which is incorporated by reference herein in its entirety.

BACKGROUND

[0002] The present disclosure relates generally to ladders and ladder rungs. Ladders are conventionally utilized to provide a user thereof with improved access to elevated locations that might otherwise be inaccessible. Ladders come in many shapes and sizes, such as straight ladders, straight extension ladders, step ladders, and combination step and extension ladders. So-called combination ladders may incorporate, in a single ladder, many of the benefits of multiple ladder designs.

[0003] In all types of ladders, it can be desirable to provide a natural and consistent climbing experience for the user, and also to provide substantial support by the rungs for a comfortable standing or climbing experience. Such characteristics can help a user in terms of potential fatigue as well as safety.

SUMMARY OF THE DISCLOSURE

[0004] The present disclosure describes embodiments of ladders, ladder rungs and methods of fabricating a ladder. In one embodiment, a ladder is provided that includes a first pair of spaced apart rails and a plurality of rungs extending between and coupled to the first pair of spaced apart rails. At least one rung of the plurality of rungs includes a first support surface portion, a second support surface portion, and a channel extending between the first support surface portion and the second support surface portion.

[0005] In one embodiment, a rear surface of each of the first pair of spaced apart rails defines a plane, and wherein the first support surface portion is located on a first side of the plane and the second support surface portion is located on a second side of the plane.

[0006] In one embodiment, first support surface portion exhibits a first depth, the channel exhibits a second depth, and the second support surface portion exhibits a third depth.

[0007] In one embodiment, at least one other rung is entirely positioned on the first side of the plane.

[0008] In one embodiment, the at least one other rung includes a support surface portion exhibits a depth that is equal to the first depth.

[0009] In one embodiment, the ladder further comprises a second assembly comprising at least one rail pivotally coupled with the first assembly and a top cap coupled to the first assembly.

[0010] In one embodiment, the at least one rung of the plurality of rungs includes at least two rungs positioned immediately adjacent to each other.

[0011] In one embodiment, each of the plurality of rungs includes a first support surface portion, a second support surface portion, and a channel extending between the first support surface portion and the second support surface portion.

[0012] In one embodiment, the channel exhibits a height of at least on 0.5 inch and a depth of at least 0.5 inch.

[0013] In one embodiment, the first depth is between approximately 2.5 inches and approximately 3.5 inches, wherein the second depth is between approximately 0.5 inch and approximately 1.0 inch, and the third depth is between approximately 1.5 inches and approximately 2.5 inches. [0014] In accordance with another embodiment of the present disclosure, a rung for a ladder is provided, the rung comprising a first support surface portion, a second support surface portion, and a channel extending between the first support surface portion and the second support surface portion.

[0015] In one embodiment, a first wall of the channel defines a plane, and wherein the first support surface portion is located on a first side of the plane and the second support surface portion is located on a second side of the plane.

[0016] In one embodiment, first support surface portion exhibits a first depth, the channel exhibits a second depth, and the second support surface portion exhibits a third depth.

[0017] In one embodiment, the first depth is between approximately 2.5 inches and approximately 3.5 inches, wherein the second depth is between approximately 0.5 inch and approximately 1.0 inch, and the third depth is between approximately 1.5 inches and approximately 2.5 inches.

[0018] In one embodiment, the channel exhibits a depth of at least approximately 0.5 inch and a height of at least one 0.5 inch.

[0019] In one embodiment, the channel extends substantially parallel to a front edge of the rung. In one embodiment, wherein rung is formed as a unitary member.

[0020] Features, elements and aspects of on embodiment may be combined with features, elements or aspects of other embodiments without limitation.

BRIEF DESCRIPTION OF THE DRAWINGS [0021] The foregoing and other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:

[0022] FIG. 1 is a perspective view of a step ladder according to an embodiment of the present invention; [0023] FIG. 2 is a side view of the step ladder shown in FIG. 1 ;

[0024] FIGS. 3 and 4 are rear and front perspective views, respectively, of a rung used in the ladder of FIG. 1 ;

[0025] FIG. 5 is a side view of the rung shown in FIGS. 3 and 4; and

[0026] FIG. 6 is a side view of another rung that can be used in the ladder shown in

FIG. 1.

DETAILED DESCRIPTION

[0027] Various embodiments of ladders and ladder components are described herein. The described embodiments are not mutually exclusive of each other. Rather, various features of one described embodiment may be used in conjunction with features of other described embodiments.

[0028] Referring to FIGS. 1 and 2, a stepladder 100 is shown in accordance with an embodiment of the present invention. The stepladder 100 includes a first assembly 102 having a pair of spaced apart rails 104 and a plurality of rungs 106 extending between, and coupled to, the rails 104. The spaced apart rungs 106 are substantially parallel to one another and are configured to be substantially level when the stepladder 100 is in an orientation for intended use so that the rungs 106 may be used as “steps” for a user to ascend the stepladder 100 as will be appreciated by those of ordinary skill in the art. In various embodiments, the upper surface of the rungs (generally denoted as 106) may include traction features (e.g., grooves and ridges, grip tape or other anti-slip features) to provide a traction to a user while standing on the rungs 106.

In the embodiment shown in FIGS. 1 and 2, two different types of rungs 106A and 106B are utilized as will described in further detail below.

[0029] The stepladder 100 also includes a second assembly 108 having a pair of spaced apart rails 110. In the embodiment shown, a plurality of cross-braces 112 extend between, and are coupled to, the spaced apart rails 110. The cross-braces 112 provide a desired level of strength and rigidity to the second assembly 108, but they are not configured as rungs (i.e., they are not intended to support a user). Thus, the second assembly 108 as shown in FIGS. 1-5 does not include a plurality of rungs between the spaced apart rails 110. However, in some embodiments, the second assembly 108 may include rungs configured generally similar to those associated with the first assembly 102. The second assembly 108 is used to help support the stepladder 100 when spaced apart from the first assembly 102 and when the ladder 100 is in an intended operational state, such as depicted in FIGS. 1 and 2. Additionally, while not specifically numbered in the drawings, it is noted that the ladder 100 may include various bracing and support members (e.g., extending between rails and associated rungs) to help provide desired strength and stability.

[0030] In the embodiment shown in FIGS. 1 and 2, the rails 104 of the first assembly 102 may be coupled with the rails 110 of the second assembly 108 by way of hinges 115. The hinges 115 may enable in the first assembly 102 and the second assembly 108 to pivot relative to one another so that the ladder 100 may be collapsed into a stowed or a stored state, and then expanded into a usable state such as shown in FIGS. 1 and 2.

[0031] The first and second assemblies 102 and 108 may be formed of a variety of materials and using a variety of manufacturing techniques. For example, in one embodiment, the rails 104 and 110 may be formed of a composite material, such as fiberglass, while the rungs and other structural components may be formed of aluminum or an aluminum alloy. In other embodiments, the assemblies 102 and 108 (and their various components) may be formed of other materials including other composites, plastics, polymers, metals and metal alloys.

[0032] A top cap 114 is coupled to the rails 104 of the first assembly 102. In one embodiment, the top cap 114 may simply be a structural component configured to facilitate relative coupling of the rails 104 of the first assembly 102. In other embodiments, the top cap 114 may include features that enable it to be used as a tray or a tool holder. Thus, the top cap 114 may be used to organize a user’s tools and resources while working on the stepladder 100. For example, such a top cap is described in U.S. Patent No. 8,186,481 issued May 29, 2012 and entitled LADDERS, LADDER COMPONENTS AND RELATED METHODS, the disclosure of which is incorporated by reference herein in its entirety. It is noted that, in the embodiment shown and described with respect to FIGS. 1 and 2, for safety purposes, the top cap 114 is not conventionally configured as a “rung” or a “step” and is not intended to support a user’s standing weight. However, in other types of ladders, including for example, those described in U.S. Patent Application No. 16/435,183 filed on Jun 7, 2019, and published as U.S. Patent Publication No. 2019/0376341 (the entire disclosure of which is incorporated by reference herein) may include a top cap that is configured for a user to stand on during use of the ladder.

[0033] As with other components of the stepladder 100, the top cap 114 may be formed from a variety of materials. In one embodiment, the top cap 114 may be formed from a plastic material that is molded into a desired size and shape. Of course other materials and manufacturing processes are also contemplated.

[0034] The step ladder 100 may additionally include a plurality of feet 116 (one associated with each rail) configured to engage a supporting surface such as the ground. The feet 116 may be configured in a variety of manners based on, for example, the type of environment in which the ladder is anticipated to be used. For example, the feet 116 may be formed of a plastic or polymer material and be configured with a plurality of ridges, knobs or other engagement features configured to provide increased friction between the ladder and a relatively rigid supporting surface (e.g., concrete, tile or wood). Additionally, or alternatively, the feet 116 may include features such as barbs or other sharp protrusions configured to dig into a relatively softer supporting surface (e.g., dirt or grass).

[0035] A pair of hinged or foldable braces, referred to herein as spreaders 120, can also be used to provide added stabilization and maintain a desired angle between the first and second assemblies 102 and 108 when the stepladder 100 is in a deployed or useable state. The hinged nature of such spreaders 120 helps to enable the first and second assemblies 102 and 108 to collapse into a stored state and then lock the assemblies 102 and 108 in position relative to one another when in a deployed or useable state. It is noted that in the embodiment shown in FIGS. 1 and 2, the spreaders 120 are not configured as rungs or platforms, and are not otherwise configured to support a user standing thereon. Rather, the spreaders 120 are simply configured to structurally maintain the ladder 100 in a deployed position while enabling the rail assemblies 102 and 108 to be selectively collapsed relative to each other for storage and transportation of the ladder 100.

[0036] As seen in FIGS. 1 and 2, the first type of rung 106A may include a portion that extends beyond the rear surfaces 122 of the rails 104 of the first assembly 102. Stated another way, the rear surfaces 122 of the rails 104 may define a plane, and a portion of the rungs 106A may extend beyond that plane toward the second assembly 108. The extended portions of these rungs 106 A provide an enlarged surface area on which a user may stand while using the ladder 100. As also seen in FIGS. 1 and 2, the first type of rung 106A, despite extending beyond the rear surfaces 122 of the front rails 104, do not directly engage or contact any portion of the second assembly 108 or the spreader mechanisms 120 when the ladder 100 is in a deployed state.

[0037] In some embodiments, such as shown in FIGS. 1 and 2, the second type of rung 106B may include rungs that do not have a portion extending beyond the rear surfaces of the rails 104. Such rungs 106B may have a depth that is equal to, or less than, a depth of the associated rails 104 as can be seen best in FIG. 2.

[0038] In some embodiments, the rungs 106 of the ladder 100 can be configured in a specific manner to minimize potential safety risks to a user of the ladder 100. For example, the rungs can be spaced and arranged such that there is a substantial space between the uppermost rung 106A and the top cap 114, discouraging and inhibiting a user from climbing on to the top cap 114. Examples of such a configuration are described in U.S. Patent Publication No.

US2015/0090533 filed on Sept. 25, 2014, the disclosure of which is incorporated by reference herein in its entirety.

[0039] Referring to FIGS. 3-5, an embodiment of the first type of rung 106A is shown. The mng includes a first support surface portion 140, a second support surface portion 142, and a channel 144 positioned between the first and second support surface portions 140 and 142. In one embodiment, the channel 142 may extend substantially parallel to the front edge 146 of the mng 106A and/or the rear edge 148 of the mng 106A. Additionally, the channel 144 may include a pair walls 148A and 148B and a floor 156. Either of the walls 148A and 148B may define a plane, wherein the first surface portion 140 and the second surface portion 142 are on opposite sides of the plane.

[0040] As can be seen in FIG. 5, the first support surface portion 140 includes a depth “Dl” that may be configured to fit within a channel portion of a rail 104 (e.g., as shown in dashed lines in FIG. 5). For example, the rail 104 may be configured with a cross-sectional profile of a C-channel, and the ends 150 of the first support surface portion 140 can be inserted or nested inside the hollow of the C-channel. Fasteners (e.g., screws, bolts, rivets, etc.) may be used to connect the first support surface portion 140 with flanges 152 of the rails 104 such as at locations indicated by the fastener openings 154 (see FIGS. 3 and 4). In other embodiments, the mngs 106A may be coupled with the rails 104 by other means, including adhesives, welding, or other appropriate joining or coupling techniques. Additionally, in other embodiments, the mng 106 need not be nested within a channel formed by the rail, but may be otherwise coupled with the rail.

[0041] As seen in FIGS. 3 and 4, the width of the first support surface portion 140 may be greater than the width of the second support surface portion 142 (with “width” being measured in a direction transverse to that of the “depth” direction). In one embodiment, this may account for the insertion of the ends of the first support surface portion 140 into the rails 104 of the first assembly 102. The width of the second support surface portion 142 may be, in some examples, at least 12 inches. In some embodiments, the width of the second support surface portion 142 may be 14 inches or greater. In the embodiment shown in FIGS. 1-5, the width of the second support surface portion 142 is substantially equal to the width of the first support surface portion 140 minus the twice the width of a rail 104, thereby providing a user with the sense that the usable width of the first and second surface portions 140 and 142 are substantially the same.

[0042] As shown in FIG. 5, the channel 144 formed in the rung 106 may have a depth D2, and the second support surface portion 142 may exhibit a depth of D3. Thus, the overall depth of the rung 106A may be equal to sum of the other depths (/. _<? ., D1+D2+D3). It is noted, with reference to FIG. 6, that the second rung type (/. _<? ., mng 106B) may have an overall depth substantially equal to D1 (/. _<? ., substantially equal to the depth of the first surface portion 140 of the first type of mng 106A). It is noted that with respect to the rungs 106, the term “depth” is a distance measured in a direction that is substantially perpendicular to the front edge 146 or the front surface of the mng and parallel to the plane defined by the upper surface portion (e.g., the first upper surface portion 140 of mng 106A).

[0043] In one embodiment, D1 may be approximately 2.5 inches to approximately 3.5 inches, D2 may be approximately 0.5 of an inch to approximately 1 inch, and D3 may be approximately 1.5 inches to approximately 2.5 inches. However, such dimensions are merely intended as examples and are not to be considered limiting in any way.

[0044] The upper surfaces of the support surface portions 104 and 142 may be configured to be substantially coplanar such that a user’s foot may extend from the first support surface portion 140, across the channel 144, and on to the second support surface portion 142, creating the sense that they are standing on a generally continual support surface. The channel 144 may also exhibit a height HI that extends from a floor portion 156 of the channel to a plane extending through the upper surfaces of the support surface portions 140 and 142. In one embodiment, the height HI of the channel 144 may be, for example, at least on 0.5 inch. In other embodiments, the height HI of the channel 144 may be between approximately 0.5 inch and approximately 1.0 inch. In other embodiments, the height HI of the channel 144 may be greater than 1.0 inch.

[0045] Referring back to FIGS. 1 and 2, the ladder 100 may include the second type of rungs 106B for several of the rungs (e.g., the lowermost rungs), while one or more of the uppermost rungs may be of the first type of rung 106 A. However, other configurations, including only a single rung of the first type 106A, or all of the rungs being of the first rung type 106 A, may be utilized.

[0046] A ladder 100 such as shown in FIGS. 1 and 2, including one or more rungs configured such as shown in FIGS. 3-5, provides various advantages. For example, the second support surface portion 142 that extends beyond the rear surfaces of the rails 104, providing additional surface area for a user to stand on. Thus, the first type of rung 106A may be used at least at a location where a user is expected to stand for an extended duration (e.g., the top-most rung, the top-most, two rungs, the lowermost mng, or the lowermost two rungs, etc.). Additionally, having a channel 144 formed within the mng between the two support surface portions 140 and 142, such as described herein, enables a user to have a climbing experience that is consistent throughout all of the rungs. For example, as a user climbs a ladder 100, their hand may grasp the rungs of the second mng type 106B in a manner such as shown as seen in FIG. 6 (see hand depicted in dashed lines). As the user grasps a mng of the first type of mng 106A, because of the channel 144 formed in the rung 106B, a user’s hand perceives the mng 106Ato be the same type of mng as the second type of mng 106B (see the user’s hand also depicted by dashed lines in FIG. 5). Thus, a user does not perceive a difference when climbing between grasping one type of rung (e.g., 106B) or the other type of rung (e.g., 106A), providing a consistent climbing experience for the user.

[0047] As previously noted, the channel 144 may exhibit a depth D2 that accommodates the fingers of a user’s hand. Thus, for example, in one embodiment, the channel may exhibit a depth D2 of at least 0.5 inch. In one embodiment, the channel 144 may exhibit a depth D2 of between approximately 0.5 inch and approximately 1.0 inch. In another embodiment, the channel 144 may exhibit a depth D2 of greater than 1.0 inch.

[0048] In some embodiments, the first type of rung 106 A may be formed as a unitary member. For example, in one embodiment, the first type of rung 106A may be formed using an extrusion process. The mng 106A may be formed of a variety of materials including, for example, aluminum, aluminum alloys, other metals, plastic materials, and composite materials.

[0049] While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Additionally, features of one embodiment may be combined with features of other embodiments without limitation. The invention includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.