Ladder, Accessory for a Ladder with a Locking Assembly, and Method

[0001] This is a nonprovisional of U.S. provisional application Ser. No. 63/091,742 filed Oct. 14, 2020, incorporated by reference herein.

[0002] The present invention is related to an accessory for a ladder which fixedly and removably attaches to a rail of the ladder by rotating a knob of a locking assembly of the accessory. (As used herein, references to the “present invention” or “invention” relate to exemplary embodiments and not necessarily to every embodiment encompassed by the appended claims.) More specifically, the present invention is related to an accessory for a ladder which fixedly and removably attaches to a rail of the ladder by rotating a knob of a locking assembly of the accessory which causes jaws of the locking assembly which are engaged with the knob to together clamp and lock the accessory to the rail.

[0003] This section is intended to introduce the reader to various aspects of the art that may be related to various aspects of the present invention. The following discussion is intended to provide information to facilitate a better understanding of the present invention. Accordingly, it should be understood that statements in the following discussion are to be read in this light, and not as admissions of prior art.

[0004] Ladders are used in a multitude of locations. In some of these locations, accessories are attached to the ladder to better conform the ladder to the location so the ladder with the accessory better assists a user to perform his or her task, or makes it safer for the user to perform his or her task, or both. In this way, a standard ladder can be adapted for many different tasks many different locations by simply attaching the accessory to the ladder. Consequently, this dictates a need for an accessory to be safely and securely attached to the ladder and to be removed from the ladder as easily and quickly as possible without damaging the ladder.

[0005] The present invention pertains to an accessory for a ladder rail with a rung. The accessory comprises a housing to be removably and fixedly attached to the rail. The accessory comprises an elongate member attached to the housing and extending beyond the housing. The accessory comprises a first locking assembly attached to the housing having a lock state which locks the housing to the rail, and an unlocked state which unlocks the housing from the rail so the housing is able to be removed from the rail.

[0006] The present invention pertains to a ladder. The ladder comprises a first rail. The ladder comprises a second rail in parallel and spaced relation with the first rail. The ladder comprises a rung attached to the first and second rails. The ladder comprises a first housing removably and fixedly attached to the first rail. The ladder comprises a second housing removably and fixedly attached to the second rail. The ladder comprises a first elongate member attached to the first housing and extending beyond the first housing. The ladder comprises a second elongate member attached to the second housing and extending beyond the second housing. The ladder comprises a first locking assembly attached to the first housing having a lock state which locks the first housing to the first rail, and an unlocked state which unlocks the first housing from the first rail so the first housing is able to be removed from the first rail. The ladder comprises a second locking assembly attached to the second housing having a lock state which locks the second housing to the second rail, and an unlocked state which unlocks the second housing from the second rail so the second housing is able to be removed from the second rail.

[0007] The present invention pertains to a method for attaching an accessory to a ladder rail with a rung. The method comprises the steps of placing a housing onto an end of the rail. The housing having an elongate member attached to the housing and extending beyond the housing. There is the step of rotating a first knob to cause a first jaw and a second jaw to directly contact and clamp and lock the housing to the rail. The first and second jaws engaged with the knob. The first and second jaws and the knob our part of a first locking assembly. The first locking assembly having a first bracket which attaches to the housing to fixedly attach the first locking assembly to the housing.

[0067] Referring now to the drawings wherein like reference numerals refer to similar or identical parts throughout the several views, and more specifically to FIGS. 1A-5B thereof, there is shown an accessory 10 for a ladder rail 12 with a rung 14. The accessory 10 comprises a housing 16 to be removably and fixedly attached to the rail 12. The accessory 10 comprises an elongate member 18 attached to the housing 16 and extending beyond the housing 16. The accessory 10 comprises a first locking assembly 20 attached to the housing 16 having a lock state which locks the housing 16 to the rail 12, and an unlocked state which unlocks the housing 16 from the rail 12 so the housing 16 is able to be removed from the rail 12.

[0068] The housing 16 may have a rung slot 22 which allows the housing 16 to fit on the rail 12 over the rung 14. The rung slot 22 may be positioned on the inside of the housing 16.

[0069] The first locking assembly 20 may have a first bracket 24 which attaches to the housing 16 to fixedly attach the first locking assembly 20 to the housing 16. The first locking assembly 20 may have a first knob 26, and a first jaw 28 and a second jaw 30 which are engaged with the knob 26 and the rail 12. Rotation of the knob 26 causes the first and second jaws 28, 30 to together clamp the rail 12 and place the first locking assembly 20 into a locked state, or causes the first and second jaws 28, 30 to separate from the rail 12 and place the first locking assembly 20 into the unlocked state. Preferably, rotation of the knob 26 in a first direction tightens the first and second jaws 28, 30 together and creates a clamp, and rotation of the knob 26 in a second direction, opposite the first direction loosens the first and second jaws 28, 30 so the housing 16 may be lifted off of the rail 12 and removed.

[0070] The housing 16 may have a first jaw slot 32 and a second jaw slot 34. The first jaw 28 positioned over the first jaw slot 32 and the second jaw 30 positioned over the second jaw slot 34 when the first locking assembly 20 is in the locked state. The first and second jaws 28, 30 together directly contact the rail through the first and second jaw slots 32, 34 and clamp the housing 16 to the rail 12. The separate first jaw slot 32 and second jaw slot 34, may be one continuous slot or have a septum 64 between them on the outside and the inside of the housing 16. The first bracket 24 may be screwed, bolted or riveted to the outside of the housing 16 between the first and second jaw slots 32, 34. The holes 66 are where the fasteners are positioned to fix a locking assembly to a rail.

[0071] The cross-section of the housing 16 may be rectangular shaped and hollow and has a perimeter which is greater than a perimeter of a cross-section of the rail 12 so the housing 16 fits about the rail 12. With the housing 16 having a rectangular shape, the rail 12 can have a rectangular shaped cross-section, such as in a box rail, or a C-shaped cross-section. In each instance, the rectangular shaped cross-section of the housing 16 will envelop the top end of the rail and provide a secure base for the first and second jaws 28, 30 to together clamp the housing 16 to the rail 12 and place the first locking assembly 20 into the locked state. The inner circumference of the housing 16 does not have to tightly conform to the outer circumference of the rail 12, because it is the first and second jaws 28, 30 which actually clamp the housing 16 to the rail 12. By the rail 12 having either a rectangular shaped cross-section or a C-shaped cross- section, there are at least two opposing sides of the rail against which the first and second jaws 28, 30 clamp. The accessory 10 works with most Werner ladder models, such as most Werner 1AA Extension ladder models. The housing 16 may have a cover 68 which fits over the top of the first ladder rail 12.

[0072] The housing 16 may have a third jaw slot 36 and a fourth jaw slot 38, and may include a second locking assembly 40 which has a second knob 42, and a third jaw 44 and a fourth jaw 46 which are engaged with the second knob 42 and the rail. Rotation of the second knob 42 causes the third and fourth jaws 44, 46 together to clamp to the rail 12 and place the second locking assembly 40 into a locked state, or causes the third and fourth jaws 44, 46 to separate from the rail and place the second locking assembly 40 into the unlocked state. The third jaw 44 positioned over the third jaw slot 36 and the fourth jaw 46 positioned over the fourth jaw slot 38. When the second locking assembly 40 is in the locked state, the third and fourth jaws 44, 46 together directly contact the rail through the third and fourth jaw slots 36, 38 and form a clamp to clamp the housing 16 to the rail 12. The second locking assembly 40 disposed below the first locking assembly 20 when the housing 16 is disposed on the rail 12. The housing 16 may be made of metal, such as aluminum. The second locking assembly 40 is like the first locking assembly 20 but is attached between the third and fourth jaw slots 36, 38 on the outside of the housing 16. There may be a septum 64 between the third and fourth jaw slots 36, 38 on the outside of the housing 16. The first bracket 24 may be positioned on the septum 64 between the first and second jaw slots 32, 34 on the outside of the housing 16, and the second bracket 70 may be positioned on the septum 64 between the third and fourth jaw slots 36, 38 on the outside of the housing 16. The rung slot 22 may be disposed below the first and second jaw slots 32, 34 and extend to the bottom of the housing 16 so the housing 16 can fit onto the first rung 14.

[0073] The elongate member 18 may be a first ladder grip 48 for a walk through. The first ladder grip 48 angles outwards away from the ladder as it extends upwards from the housing 16. The first ladder grip 48 comprises a first section 72 which attaches to the side of the housing 16, a second section 74 which connects to and extends from the first section 72 and angles outwards away from the ladder between 20° and 60° and a third section 76 which connects to and extends from the second section 74, as shown in FIG. 30. The first, second and third sections may each be straight, may be one continuous piece and made of metal, such as aluminum. The first ladder grip 48 may be hollow. There may be a second ladder grip 78 for a walk through, identical to the first ladder grip 48 for a walk through, which attaches to a second rail 80 of the ladder 100.

[0074] The elongate member 18 may have a first elongate slot 50 which aligns with the first jaw slot 32 through which the first jaw 28 extends to contact the rail 12. The elongate member 18 may have a second elongate slot which aligns with the third jaw slot 36 through which the third jaw 44 extends to contact the rail 12. The housing 16 may have a handle 52. The handle 52 may be attached with screws or rivets to the housing 16. The housing 16 may have a latch 54 which is positioned under the rung 14 when the housing 16 is disposed on the rail 12 which prevents the housing 16 from slipping off the rail 12.

[0075] The present invention pertains to a ladder 100, as shown in FIG. 57. The ladder 100 comprises a first rail 12. The ladder 100 comprises a second rail 80 in parallel and spaced relation with the first rail 12. The ladder 100 comprises a rung 14 attached to the first and second rails. The ladder 100 comprises a first housing 16 removably and fixedly attached to the first rail 12. The ladder 100 comprises a second housing 102 removably and fixedly attached to the second rail 80. The ladder 100 comprises a first elongate member 18 attached to the first housing 16 and extending beyond the first housing 16. The ladder comprises a second elongate member 104 attached to the second housing 102 and extending beyond the second housing 102.

[0076] The ladder 100 comprises a first locking assembly 20 attached to the first housing 16 having a lock state which locks the first housing 16 to the first rail 12, and an unlocked state which unlocks the first housing 16 from the first rail 12 so the first housing 16 is able to be removed from the first rail 12. The ladder 100 comprises a second locking assembly 40 attached to the first housing 16 having a lock state which locks the first housing 16 to the first rail 12, and an unlocked state which unlocks the first housing 16 from the first rail 12 so the first housing 16 is able to be removed from the first rail 12. The ladder 100 comprises a second locking assembly 40 attached to the second housing 102 having a lock state which locks the second housing 102 to the second rail 80, and an unlocked state which unlocks the second housing 102 from the second rail 80 so the second housing 102 is able to be removed from the second rail 80. As shown in FIG. 57, the first and second rails of the ladder 100 are disposed against the edge 126 of the roof 128 of a building 130. The first and second accessories, attached to the top ends of the first and second rails, extend well above the roof 128. Elongate members of the accessories provide handles for a user to grip to provide support as the user steps off the ladder 100 to the roof 128.

[0077] The present invention pertains to a method for attaching an accessory 10 to a ladder rail 12 with a rung 14. The method comprises the steps of placing a housing 16 onto an end of the rail 12. The housing 16 having an elongate member 18 attached to the housing 16 and extending beyond the housing 16. There is the step of rotating a first knob 26 to cause a first jaw 28 and a second jaw 30 to directly contact and clamp and lock the housing 16 to the rail 12. The first and second jaws 28, 30 engaged with the knob 26. The first and second jaws 28, 30 and the knob 26 are part of a first locking assembly 20. The first locking assembly 20 having a first bracket 24 which attaches to the housing 16 to fixedly attach the first locking assembly 20 to the housing 16.

[0078] In one embodiment, where a first accessory 10 and a second accessory 11 are used, where each accessory has a ladder grip as an elongate member, the first and second accessories together serve as an over-the-rail extension accessory that uses a multi-point clamping system that easily and securely holds the first and second accessories to the ladder 100. Each locking assembly effectively eliminates movement or play in all directions. The oversized knob and lift bracket geometry allow the clamp formed by the first and second jaws 28, 30 to apply the necessary clamping force without damaging the rail 12 of the ladder 100. The same applies for the third and fourth jaws 44, 46 and for the second accessory 11 disposed on the second rail 80 of the ladder 100.

[0079] FIGS. 1A and 1B show the clamp formed from the first and second jaws 28, 30 in the open position. Key operative components are the knob and jaws.

[0080] FIGS. 2A and 2B show the clamp formed from the first and second jaws 28, 30 after the knob has been turned clockwise and the jaws have moved closer together. When installed on a ladder, the jaws would be tightly gripping the ladder rail 12.

[0081] FIG. 3 shows a first accessory 10 and a second accessory 11, a RH and LH, about to be installed on a ladder. All four clamps formed from the four locking assemblies are wide open.

[0082] FIGS. 4A and 4B show the accessories in place but the clamps still wide open.

[0083] FIGS. 5A and 5B show the clamps having been tightened by turning the knobs and the clamp jaws tightly gripping the ladder rails 12.

[0084] FIGS. 6A-6F show multiple views of the LH Walk Through accessory embodiment. The RH version is a mirror image. The elongate member 18 is preferably welded to the side of the housing 16, although rivets or bolts may also be used to fixedly and permanently directly attach the elongate member 18 to the housing 16.

[0085] FIG. 7 is a side view of a second jaw 30. The second jaw 30 is C-shaped to form a hook, and the opposing first jaw 28 together when they are closed around the rail by turning the knobs, form a vice or clamp about the first rail 12, securely and tightly holding the housing 16 to the first rail 12, without movement. The second jaw 30 is cast and has a depression 33. The cross section across the depression 33 may be considered as having an I-beam type cross section. The depression 33 serves to reduce the amount of material needed to produce the second jaw 30. FIG. 8 is a front view of a second jaw 30. FIG. 9 shows a gnarled surface 106 of the second jaw 30. The gnarled surface 106 directly contacts the first rail 12. The gnarled surface 106 acts as a tread to better grip the first rail 12. The gnarled surface 106 of each jaw, which is flat, compresses against a flat surface of an opposing side of the first rail 12, whether it be opposing sides of a box shaped rail or opposing flanges of a c-shaped rail. That is, the flat gnarled surface of the second jaw 30 conforms with the flat surface of the first rail 12 against which it squeezes as it is tightened with the turning of the knob 26. FIG. 58 shows an alternative embodiment of the second jaw 30. In the alternative embodiment the second jaw 30 is an extruded profile which has three gaps 35 to reduce the amount of material needed to produce the second jaw 30 and consequently its weight. The reason for the change from depressions 33 to gaps 35 is the nature of the production processes. For extrusion and extruded parts, the through-all gaps 35 is the best way to reduce mass while maintaining the required strength since a fixed-shaped profile can only be extruded. The aforementioned description of the second jaw 30 is representative of all jaws herein and is applicable for all jaws.

[0086] FIG. 10 is a perspective view of a bracket 24. FIG. 11 is a side view of the bracket 24. FIG. 12 is a bottom view of the bracket 24. FIG. 13 is a perspective view of a lift bracket 25 which fits into the bracket 24. The first and second jaws 28, 30 fit into the openings of the lift bracket 25. FIG. 14 is a side view of a lift bracket 25. FIG. 15 is a bottom view of a lift bracket 25.

[0087] FIG. 16 is a perspective view of a square nut 27 of the locking assembly which fits onto the lift bracket and through which a stem 108 of the knob 26 extends. FIG. 17 is a perspective view of a retaining ring 110 of the locking assembly. FIG. 18 is a perspective view of a nylon flat washer 112 of the locking assembly 20.

[0088] FIG. 19 is a bottom perspective view of the knob 26. FIG. 20 is a top perspective view of the knob 26. FIG. 21 is a bottom perspective view of the knob 26 with the stem 108. FIG. 22 is a bottom view of the knob 26 with the stem 108 and the retaining ring 110. FIG. 23 is a cross-sectional view of the knob 26—stem 108—retaining ring 110 of FIG. 22. FIG. 24 is a side view of the knob 26 and stem 108

[0089] FIG. 25 is a perspective view of the locking assembly 20. FIG. 26 is a side view of the locking assembly 20. FIG. 27 is a front view of the locking assembly 20. The carriage bolt 114 extends through a first wall 120 of the first bracket 24, through a spring 118, through a second wall 122 of the first bracket 24 and a hex nut 116. The same structure is applicable regarding a second carriage bolt 114 on the other side of the bracket 24. FIG. 28 is a cross-sectional view of the locking assembly 20 of FIG. 27.

[0090] FIG. 29 is a side view of an elongate member 18 which is an arm of a walk through. FIG. 30 is a front view of a right-hand arm of the walk through. The first elongate slot 50 and the second elongate slot 51 of the elongate member 18. The left-hand arm is a mirror image of the right-hand arm.

[0091] FIG. 31 is a front perspective view of the housing 16. FIG. 32 is a rear perspective view of the housing 16. FIG. 33 is a side view of the housing 16.

[0092] FIG. 34 is a perspective view of a backup pad 120. FIG. 35 is a perspective view of a hollow end rivet 122 showing the hollow region with dashed lines. FIG. 36 is a perspective view of the hollow end rivet 122.

[0093] FIG. 37 is a front perspective view of the housing 16 with a handle 52. FIG. 38 is a front view of the housing 16 with the handle 52. FIG. 39 is a side view of the left-hand housing 16 with the handle 52. FIG. 40 is a rear view of the housing 16 with the handle 52. The right-hand housing 102 with the handle 52 is a mirror image. FIG. 41 is a perspective view of the housing 16 with the elongate member 18 attached. The jaw slots of the elongate member 18 align with the corresponding jaw slots of the housing 16. FIG. 42 is a side view of the housing 16 with the elongate member 18. FIG. 43 is a front view of the left-hand housing 16 with the elongate member 18. The right-hand housing 102 with the elongate member 18 is a mirror image.

[0094] FIG. 44 is an outside view of a left-hand accessory 10. FIG. 45 is a front view of a left-hand accessory 10. FIG. 46 is an inside view of a left-hand accessory 10. FIG. 47 is an outside view of a right-hand accessory 10. FIG. 48 is a front view of a right-hand accessory 10. FIG. 49 is an inside view of a right-hand accessory 10.

[0095] FIG. 50 is a perspective view of the latch 54. The latch 54 has a bottom surface 56 which is angled upwards, preferably at about 45° from the horizontal. See FIG. 50. As the first accessory 10 is fitted over the top of the first rail and moves down the first rail, the bottom surface 56 of the latch 54 contacts the first rung 14, and is cammed aside the first rung 14 as the first accessory 10 continues to move down the first rung 14 and compresses the latch spring 59 until the latch 54 clears the first rung 14. Once the latch 54 clears the first rung 14, the latch spring 59 shown in FIG. 53, under the force of the latch spring 59 now decompressing, since the latch 54 is no longer being cammed by the first rung 14, moves back into a stable position with the horizontal flat top surface 58 of the latch 54 underneath the first rung 14. See FIGS. 46 and 47. By the horizontal flat the top surface 58 of the latch 54 being underneath the first rung 14, the first accessory 10 is blocked by the latch 54 from being lifted off or coming off of the first rail. This is because the horizontal flat top surface 58 of the latch 54 contacts the bottom of the first rung 14 when the first accessory 10 tries to be removed from the first rail, and the latch 54 is moved downward in a clockwise direction and contacts the first bracket 24, which effectively acts as a stop, preventing the latch 54 from moving downward any further, thus preventing the first accessory 10 from coming off of the first rail. In order for the first accessory 10 to be removed from the first rail, the first locking assembly 20 and the second locking assembly 40 must be loosened so their jaws no longer grip the first rail, and the latch 54 must be moved in a counterclockwise direction so the bottom surface 56 faces the first rung 14. In this position, as the first accessory 10 is lifted off of the first rail, the first rung 14 cams the bottom surface 56 and rotates the latch 54 out of the way of the first rung 14 so the latch 54 no longer blocks the first accessory 10 from coming off of the first rail. The latch spring 59 is fitted to the inside of the latch 54. The latch 54 is rotatably attached to the housing 16 with a shoulder rivet 60 extending through a latch hole 62 and anchoring to the housing 16.

[0096] FIG. 51 is a front view of the latch 54. FIG. 52 is a perspective view of a steel shoulder. FIG. 53 is a perspective view of a latch spring 59. FIG. 54 is a side view of a left-hand latch spring 59. FIG. 55 is a side view of a left latch spring 59. The right latch 54 is a mirror image. FIG. 56 is an effective view of a square nut carriage bolt 114.

[0097] Although the invention has been described in detail in the foregoing embodiments for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be described by the following claims.