LADDER, TOP AND METHOD

Abstract

A ladder having a first rail. The ladder having a second rail. The ladder having a plastic top directly attached to the first rail and second rail with fasteners. The top having a first side and a second side. The first side having a gap with a surface with a V so a corner can fit into the V when the top leans against the corner. The surface of the first side having a first notch in the gap so a first rectangular plank can fit into the first notch when the top leans against the plank. The first notch having a width slightly larger than a width of the first plank. A ladder top. A method for using a ladder.

Claims

1.-15. (canceled)

16. A ladder top for a ladder, the ladder top comprising: a ladder top body to be coupled to one or more ladder rails, the ladder top body having a top wall, a front wall, a first end wall, and a second end wall, the front wall, the first end wall, and the second end wall extending from the top wall, the front wall extending between the first end wall and the second end wall; the front wall including a recess to receive at least a portion of a support against which the ladder top is leaned, a flat front surface, a first flat corner surface extending obliquely between the flat front surface and the first end wall, and a second flat corner surface extending obliquely between the flat front surface and the second end wall; and a plurality of pads separate and spaced apart from one another along the front wall to inhibit the front wall from contact with a surface against which the ladder top is leaned, wherein a first pad of the plurality of pads extends from the flat front surface to the first flat corner surface and a second pad of the plurality of pads extends from the flat front surface to the second flat corner surface.

17. The ladder top of claim 16 wherein the recess includes a first recess sidewall and a second recess sidewall, the first recess sidewall including one or more support engaging notches and the second recess sidewall including one or more corresponding support engaging notches.

18. The ladder top of claim 16 wherein the recess includes first recess sidewall and a second recess sidewall extending at an approximately 90 degree angle relative to one another, wherein a third pad of the plurality of pads is disposed on the first recess sidewall and a fourth pad of the plurality of pads is disposed on the second recess sidewall.

19. The ladder top of claim 16 wherein the recess is sized to receive a portion of an external corner of a wall or a vertical post.

20. The ladder top of claim 16 wherein the first pad and the second pad are configured to contact a wall when the ladder top is leaned against the wall, and wherein at least a portion of the first pad and the second pad are substantially parallel to one another.

21. The ladder top of claim 16 wherein the first pad and the second pad are configured to contact each side of an internal corner when the ladder is leaned against the internal corner.

22. The ladder top of claim 16 wherein the plurality of pads are coupled to the front wall using adhesive.

23. The ladder top of claim 16 wherein the plurality of pads are coupled to the front wall using both mechanical and chemical bonds.

24. The ladder top of claim 16 wherein the first pad extends from the first end wall of the ladder top body to the recess and the second pad extends from the second end wall of the ladder top body to the recess.

25. The ladder top of claim 16 wherein the first pad and the second pad together span approximately a full length of the flat front surface.

26. The ladder top of claim 16 wherein the front wall including openings configured to receive protrusions of the plurality of pads to couple the plurality of pads to the front wall, the protrusions formed as a single piece with the respective pad.

27. The ladder top of claim 16 wherein the first pad and the second pad each include at least two protrusions and the front wall includes at least two corresponding openings for the at least two protrusions on each of the first pad and the second pad.

28. A ladder top comprising: a ladder top body including a first sidewall, a second sidewall, and a front wall extending between the first sidewall and the second sidewall; the front wall including a first portion and a second portion forming a flat front surface, the first portion and the second portion spaced apart by a recess sized to receive at least a portion of a support against which the ladder top is leaned; the recess formed by a first recess sidewall and a second recess sidewall, the first recess sidewall extending from the first portion of the front wall to the second recess sidewall and the second recess sidewall extending from the first recess sidewall to the second portion of the front wall; the first recess sidewall including one or more support engaging notches and the second recess sidewall including one or more corresponding support engaging notches; a plurality of pads disposed along the front wall to cushion the front wall from contact with a surface against which the ladder top is leaned, the plurality of pads including a first pad disposed on the first recess sidewall and a second pad disposed on the second recess sidewall.

29. The ladder top of claim 28 wherein the first pad and the second pad are configured to contact portions of a wall when the ladder top is leaned against an external corner of the wall.

30. The ladder top of claim 28 wherein the one or more support engaging notches of the first recess sidewall includes a first notch and a second notch, the first pad between the first notch and the second notch.

31. The ladder top of claim 28 wherein the front wall includes openings to secure the plurality of pads to the front wall.

32. The ladder top of claim 31 wherein the plurality of pads include protrusions extending in the openings to couple the plurality of pads to the front wall.

33. The ladder top of claim 28 wherein the front wall includes a first flat corner surface and a second flat corner surface, the first flat corner surface extending from the flat front surface to the first sidewall, and the second flat corner surface extending from the flat front surface to the second sidewall.

34. The ladder top of claim 33 wherein the plurality of pads includes a third pad that extends from the flat front surface to the first flat corner surface and a fourth pad that extends from the flat front surface to the second flat corner surface.

35. The ladder top of claim 34 wherein the third pad and the fourth pad are configured to contact portions of a wall when the ladder top is leaned against an internal corner of the wall.

36. The ladder top of claim 28 wherein the first sidewall includes one or more openings to secure the first sidewall to a first ladder rail and the second sidewall includes one or more openings to secure the second sidewall to a second ladder rail.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0008] In the accompanying drawings, the preferred embodiment of the invention and preferred methods of practicing the invention are illustrated in which:

[0009] FIG. 1 shows an overhead view of a ladder top of the present invention.

[0010] FIG. 2 shows a ladder with the ladder top.

[0011] FIG. 3 shows an underside view of the ladder top.

[0012] FIG. 4 shows a front view of the ladder top.

[0013] FIG. 5 shows an overhead view of the ladder top against an external corner.

[0014] FIG. 6 shows an overhead view of the ladder top against a first rectangular plank.

[0015] FIG. 7 shows an overhead view of the ladder top against a second rectangular plank.

[0016] FIG. 8 is an overhead view of the ladder top against an internal corner.

[0017] FIG. 9 is an overhead view of the ladder top against a wall.

[0018] FIG. 10 is a perspective view of a stepladder of the present invention.

[0019] FIG. 11 is a perspective view of an alternative embodiment of the ladder top.

[0020] FIG. 12 is a top view of the alternative embodiment of the ladder top.

[0021] FIG. 13 is a left side view of the alternative embodiment of the ladder top.

[0022] FIG. 14 is a bottom view of the alternative embodiment of the ladder top.

[0023] FIG. 15 is a bottom view of a second alternative embodiment of the ladder top.

[0024] FIG. 16 is a front view of the second alternative embodiment of the ladder top.

[0025] FIG. 17 is a right side view of the second alternative embodiment of the ladder top.

[0026] FIG. 18 is a left side view of the second alternative embodiment of the ladder top.

[0027] FIG. 19 is an overhead view of the second alternative embodiment of the ladder top.

[0028] FIG. 20 is a rear view of the second alternative embodiment of the ladder top.

[0029] FIG. 21 shows a front perspective view of the second alternative embodiment of the ladder top.

[0030] FIG. 22 shows a rear perspective view of the second alternative embodiment of the ladder top.

DETAILED DESCRIPTION OF THE INVENTION

[0031] Referring now to the drawings wherein like reference numerals refer to similar or identical parts throughout the several views, and more specifically to FIGS. 1-4, thereof, there is shown a ladder 10. The ladder 10 comprises a first rail 12. The ladder 10 comprises a second rail 14. The ladder 10 comprises a plastic top 16 directly attached to the first rail 12 and second rail 14 with fasteners 78. The top 16 has a first side 18 and a second side 20. The first side 18 has a gap 22 with a surface 24 with a V 26 so an external corner 28, as shown in FIG. 5 can fit into the V 26 when the top 16 leans against the corner 28. The surface 24 of the first side 18 has a first notch 30 in the gap 22 so a first rectangular plank 34 can fit into the first notch 30 when the top 16 leans against the plank, as shown in FIG. 6. The first notch 30 has a width slightly larger than a width of the first plank 34. The top 16 having a first cushion 70 bonded to the first side without any mechanical fasteners.

[0032] The first notch 30 may be in the V 26. The surface 24 of the first side 18 may have a second notch 32 in the gap 22 having a width greater than the width of the first notch 30 so a second rectangular plank 36 having a width slightly smaller than the width of the second notch 32 can fit into the second notch 32 when the top 16 leans against the second plank 36, as shown in FIG. 7. The second notch 32 may be in the V 26.

[0033] The surface 24 of the first side 18 may have a first straight segment 38, a second straight segment 40, a third straight segment 42, a fourth straight segment 44, a fifth straight segment 46, a sixth straight segment 48, a seventh straight segment 50 and an eighth straight segment 52, as shown in FIG. 1. The second straight segment 40 may directly connect with the first straight segment 38 to form a bottom 88 of the V 26. The third straight segment 42 may directly connect with the first straight segment 38 at an angle greater than 100 and less than 170. The fourth straight segment 44 may directly connect with the second straight segment 40 at an angle greater than 100 and less than 170. The fifth straight segment 46 may directly connect with the third straight segment 42 at an angle of about 90. The sixth straight segment 48 may directly connect with the fourth straight segment 44 at an angle of about 90. The third, fourth, fifth and sixth straight segments 42, 44, 46, 48 together forming the first notch 30.

[0034] The surface 24 of the first side 18 may have a ninth straight segment 54, a tenth straight segment 56, an eleventh straight segment 58 and a twelfth straight segment 60. The eleventh straight segment 58 may directly connect with the ninth straight segment 54 at an angle of about 90. The twelfth straight segment 60 may directly connect with the tenth straight segment 56 at an angle of about 90. The ninth, tenth, eleventh and twelfth straight segments 54, 56, 58, 60 together forming the second notch 32 in the gap 22 having a width greater than the width of the first notch 30 so the second rectangular plank 36 having a width slightly smaller than the width of the second notch 32 can fit into the second notch 32 when the top 16 leans against the second plank 36.

[0035] The surface 24 of the first side 18 may have a thirteenth straight segment 62 and a fourteenth straight segment 64. The thirteenth straight segment 62 may directly connect with the fifth straight segment 46 and the ninth straight segment 54 and is in linear alignment with the first straight segment 38. The fourteenth straight segment 64 may directly connect with the sixth straight segment 48 and the tenth straight segment 56 and is in linear alignment with the second straight segment 40.

[0036] The first cushion 70 may be attached to the surface 24 of the first side 18 in the gap 22 at the thirteenth straight segment 62 and a second cushion 72 attached to the surface 24 of the first side 18 in the gap 22 at the fourteenth straight segment 64. The first and second cushions 70, 72 protect the corner 28 from being scratched or marred by the top 16 when the top 16 leans against the corner 28. The top 16 may have a third side 84 directly connected to the first side 18 and the second side 20 and a fourth side 86 directly connected to the first side 18 and the second side 20. The first rail 12 may be permanently attached with a first fastener 80 to the third side 84 and the second rail 14 maybe permanently attached with a second fastener 82. The ladder 10 may include a third cushion 74 attached to the surface 24 of the first side 18 at the seventh straight segment 50 and a fourth cushion 76 attached to the surface 24 of the first side 18 at the eighth straight segment 52.

[0037] The top 16 may have a middle portion 92 disposed between a perimeter 94 of the top 16 defined by the first, second, third and fourth sides 18, 20, 84, 86. The middle portion 92 may have a paint can indentation 96 to hold a paint can, and a tool hole 90 to hold a tool, such as a screwdriver or pliers or drill. There may be several tool holes 90 in the middle portion 92 to accommodate a number of different types of tools.

[0038] The surface 24 of the first side 18 may have a fifteenth straight segment 66 that directly connects with the third side 84 and to the seventh straight segment 50 at an angle between 20 and 70, and a sixteenth straight segment 68 that directly connects with the fourth side 86 and the eighth straight segment 52 at an angle between 20 and 70. As shown in FIG. 8, the angular position of the seventh and eighth straight segments allow the seventh and eighth straight segments, and thus the top 16, to fit stably against an internal corner 98 when the top 16 leans against an internal corner 98. Additional cushions may be used as desired along the first side 18. When leaning against a wide surface, such as a wall 100 as shown in FIG. 9, the third cushion on the seventh straight segment and the fourth cushion on the eighth straight segment of the top 16 will rest against the wall 100.

[0039] The present invention pertains to a top 16 for a ladder 10 to be leaned against a first rectangular plank 34 or an external corner 28. The top has a first rail and a second rail. The top comprises a middle portion 92 having a perimeter 94 with a first side 18, second side 20, third side 84 and fourth side 86 extending down from the perimeter 94. The first side 18 has a gap 22 with a surface 24 with a V 26 so a corner 28 can fit into the V 26 when the top 16 leans against the corner 28. The surface 24 of the first side 18 having a first notch 30 in the gap 22 so a first rectangular plank 34 can fit into the first notch 30 when the top 16 leans against the plank 34. The first notch 30 has a width slightly larger than a width of the first plank 34. The top 16 being one piece and made of plastic and the cushions made of rubber. The third side 84 having a first fastener hole 102 to receive a first fastener 80 to permanently attach the first rail 12 to the third side 84. The fourth side 86 has a second fastener hole 104 to receive a second fastener 82 to permanently attach the second rail 14 to the fourth side 86.

[0040] As shown in FIGS. 4 and 5, the top 16 has a first flap 120 having a rectangular shape which conforms with the shape of the top side of the first rail 12, and having a first fastener hole 102 and a second fastener hole 104 that receives a first fastener 78 and a second fastener 80, respectively, to fasten the first flap 122 to the inner top side of the first rail 12. The first flap 120 extends down from the middle portion 92 of the top 16 near to and inside of the third side 84. The third side 84 has an L shape with a flat portion 122 that lines with and turns into the first side 18, and a lower portion 124 that extends down from the flat portion 122. The second side 20 extends down from the perimeter 94 the same distance is the lower portion extends down from the perimeter and forms a smooth continuous surface with the lower portion. In the space created between the first flap 120 and the lower portion 124 the top side of the first rail 12 fits and is essentially protected somewhat on the outside from the lower portion 124 and at the front from the second side 20 and from the inside by the first flap 120. The second rail 14 is similarly attached to a second flap 130 in spaced relationship with the fourth side 86. In this manner, the top 16 attaches to the first and second rails of an extension ladder.

[0041] In this manner, the ladder top 16 can also be attached to a step ladder 140, as shown in FIG. 10, where the stepladder has a first hinge 150 that attaches to and extends from the first rail 12 and a second hinge 152 that attaches to and extends from the second rail 14. The first and second hinges are in spaced relation with the ladder top 16. A third rail 154 attaches to the first hinge 150 and a fourth rail 156 attaches to the second hinge 152. The third rail 154 in the fourth rail 156 are able to move between an open, use position, and a closed position with the first hinge 150 and second hinge 152, respectively, as is well known in the art. There are rungs attached to the third and fourth rails, as well as brackets which fold attached between the first rail 12 and the third rail 154, and between the second rail 14 and the fourth rail 156. When the stepladder is in a closed position, with the rails essentially in parallel with each other, the stepladder can be leaned on the top 16 against structures, such as described above, with the notches for planks and the V shape for an external corner and the angled corner segments for an internal corner, and be more securely kept in position without sliding or falling over.

[0042] FIGS. 11-14 show another embodiment of the top 16 that is preferably used with the stepladder embodiment. Note, there are no flaps, but instead, the first rail 12 attaches to the third side 84 with fasteners 78 extending through fastener holes in the third side 84; and the second rail 14 attaches to the fourth side 86 with fasteners 78 extending through fastener holes in the fourth side 86.

[0043] FIGS. 15-22 show a second alternative embodiment of the top 16 having bungee slots 180 in the third side 84 and forth side 86 for holding tools with bungee straps. In addition, a magnet 170 is completely encapsulated in the top 16, as shown in FIGS. 15 and 19. When the top 16 is being formed, the magnet, which is a single solid element, is placed on pins in the mold so that when the molten plastic fills the mold it encompasses the magnet.

[0044] The present invention pertains to a method for using a ladder 10. The method comprises the steps of moving the ladder 10 to a first rectangular plank 34. There is the step of leaning the ladder 10 against the first rectangular plank 34 so the rectangular plank 34 is disposed in a first notch 30 in a gap 22 in a first side 18 of a plastic top 16 directly attached to a first rail 12 and a second rail 14 with fasteners 78. The top 16 has a second side 20. The first side 18 has the gap 22 which has a surface 24 with a V 26 so a corner 28 can fit into the V 26 when the top 16 leans against the corner 28. The surface 24 of the first side 18 having the first notch 30 in the gap 22. The first notch 30 having a width slightly larger than a width of the first plank 34.

[0045] In the operation of the invention, in one embodiment, a molded top 16 fits on the upper rail ends of the fly section of an extension ladder 10. The top 16 has locations at its middle portion 92 to permit the temporary placement of tools when the user is working at the upper end of the ladder 10. The back or first side 18 of the top 16 is specifically designed so that the ladder 10 may be leaned against a wide flat surface, such as a wall 100 as shown in FIG. 9, may be leaned against an external corner 28 as shown in FIG. 5, and may be leaned against and closely engage a rectangular plank, such as 6 wide or 4 wide lumber as shown in FIGS. 6 and 7.

[0046] When leaning against an external corner 28, the V shape of the external corner 28 fits into the V 26 of the top 16 formed by the first straight segment 38 and the second straight segment 40. The first straight segment 38 directly connects with the second straight segment 40, typically at an angle of about 90, to match a typical external corner 28. In addition, the external corner 28, when the top 16 is leaning against the corner 28 and the external corner 28 is in the gap 22, the external corner 28 also contacts the first cushion 70 on the thirteenth straight segment 62, which is in linear alignment with the first straight segment 38, and the second cushion 72 which is on the fourteenth straight segment 64 which is in linear alignment with the second straight segment 40. By being in linear alignment with the first and second straight segments 38, 40, the thirteenth straight segment 62 and the fourteenth straight segment 64, respectively, effectively extend the length of the V 26 to provide a larger V and thus a larger surface area for the top 16 to rest against and consequently a more secure and stable fit of the top 16 with the external corner 28.

[0047] Similarly, when the top 16 leans against an internal corner 98, the fifteenth straight segment 66 and the sixteenth straight segment 68, which directly connect to and form an angle of about 45 with the seventh straight segment 50 and the eighth straight segment 52, respectively, stably rest against and align with the walls that form the internal corner 98. In this way the top can be disposed in an internal corner for a user to use, with a greater surface area of the top 16 contacting the walls of the internal corner 98 than if the fifteenth and sixteenth straight segments did not exist or were not that about a 45 angle relative to the seventh and eighth straight segments.

[0048] The first notch 30 and the second notch 32 are disposed in, or integrated with and break up the V 26 in the gap 22. The first notch 30 conforms to the rectangular cross-section of a rectangular plank, such as a 4 inch wide plank. The first notch 30 is slightly larger in width than the width of the 4 inch plank so that when the top 16 leans against the 4 inch plank, the first notch 30 receives the 4 inch plank rather snuggly so there is essentially no movement between the top 16 and the 4 inch plank and the top 16 is stably positioned with the 4 inch plank.

[0049] Similarly, the second notch 32 conforms to the rectangular cross-section of a rectangular plan, such as a 6 inch wide plank. The second notch 32 is slightly larger in width than the width of the 6 inch plank so that when the top 16 leans against the 6 inch plank, the second notch 32 receives the 6 inch plank rather snuggly so there is essentially no movement between the top 16 and the 6 inch plank top 16 is stably positioned with the 6 inch plank.

[0050] Outside the gap 22 on either side of the top 16 there is a third cushion 74 and forth cushion which will contact a flat section, such as a wall, when the top 16 leans against the wall. The third and fourth cushions 74, 76 protect the wall from being marred or scratched by the top 16 when the top 16 leans against the wall.

[0051] The ladder top 16 with the cushions or pads is formed from 2 distinct materials. A mold utilizing a rotating platen to process two materials in the same part produces the ladder top 16 with the cushions. The ladder top 16 is made of polypropylene and the soft rubber pads or cushions are made of a ThermoPlastic Vulcanizate (TPV), specifically under the brand name Santoprene (TPV). In the production process, a mold for the top 16 receives the molten plastic. A removable portion of the mold creates cavities in the first side 18 where the cushions will ultimately be located. After the top 16 is formed, it stays in the stationary portion of the mold and the removable portion of the mold is replaced with a second removable portion of the mold. The overall mold is then closed and liquid TPV is introduced into the mold to fill the cavitys that are then present in the preformed top 16. The TPV is allowed to cool resulting in the presence of the cushions with the top 16. These cushions form both mechanical and a chemical bond with the top 16, for added strength to prevent the cushions from separating from the first side 18. The molten TPV chemically reacts with the polypropylene to create the chemical bond, as well as with the cooling TPV forming a mechanical bond.

[0052] The rails and the rungs themselves are standard commonly available components. The width of the top 16 is preferably between 13 and 20 inches. The length of the ladder top is between 5 and 10 inches. The height of the ladder top is between 2 and 7 inches. The thickness of the ladder top is between of an inch and of an inch. Buttressing (each rib being between 0.1 and 0.2 inches thick) underneath the top 16 can be utilized as shown in the figures. The ladder 10 with any of the embodiments described herein of the top 16 when leaning against a surface at 75.5 can support a load on the ladder of at least 600 pounds without failing.

[0053] 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.