Abstract:
A step ladder, includes a first ladder frame and a second ladder frame operably pivotably coupled to the first frame intermediate the second ladder frame, the second ladder frame being formed of a unitary loop defining a step portion and a handle section, the step portion and a handle section being coupled a first bend and a second generally reverse bend. A method of forming a step ladder is further included.

Description:
REFERENCE TO RELATED APPLICATION  
       [0001]     The present application is a continuation application of U.S. patent application Ser. No. 11/441,813, filed May 26, 2006, which is a divisional application of U.S. patent application Ser. No. 10/390,550, filed Mar. 17, 2003, now U.S. Pat. No. 7,128,187 B2, issued Oct. 31, 2006 and claims the benefit of U.S. Provisional Patent Application No. 60/364,893, filed Mar. 15, 2002, each hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     Step ladders are generally known in the art. Kummerlin, U.S. Pat. No. 4,502,564, discloses a foldable step ladder. Because of their desired portability, foldable step ladders often include handles and other features that make them easier to transport. Lucci, U.S. Pat. No. 3,744,591, discloses a portable, folding step ladder.  
         [0003]     When working on a step ladder, it is often desirable to have tools, paint and other necessary objects within easy reach. For example, it is known to removably attach a paint roller tray to the rung of a ladder to more easily paint a ceiling or other area requiring a ladder or step stool. Golden, U.S. Pat. No. 3,625,388, discloses a paint tray particularly useful with an upright ladder.  
         [0004]     Utility trays for use with step ladders are also known in the art. Pham, U.S. Pat. No. 5,673,885, discloses a paint tray for a step ladder for storing work materials, tools and a paint bucket that is held onto the ladder by retaining means. Melanson, U.S. Pat. No. 5,613,574, discloses a ladder mounted tool holster and parts tray that removably clamps onto the top step of a step ladder. Katz et al., U.S. Pat. No. 6,443,260, discloses a step ladder tray pivotally attached to the top cap of a step ladder for supporting tools and the like. Christ et al., U.S. Pat. No. 5,052,581, discloses a detachable ladder support tray for supporting tools and paint containers.  
         [0005]     It is often inconvenient, however, to use a removable tool or paint tray with a step ladder. In some instances, the tray may be difficult to attach or remove from the step ladder. The removable tray and step ladder usually must be stored separately, taking up additional space. Additionally, to move a step ladder from place to place, the tray may need to be removed and carried separately because of weight or awkward transport configuration. Further, a means of steadying oneself when mounted on the step ladder is important for safe use of the tools, etc. disposed in the tray.  
         [0006]     There is a need in the industry to have an erect handle section for supporting the tray and for supporting the user of the step ladder.  
       FIELD OF THE INVENTION  
       [0007]     The present invention relates generally to ladders. More particularly, the present invention relates to a step ladder.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention substantially meets the aforementioned needs of the industry. By providing two bends in a ladder frame, a handle section that is erect when the step ladder is in the open disposition may be readily formed. A frame of the ladder of the present invention has a pair of side posts and an upper handle section that extends between the pair of side posts. The upper handle section extends sufficiently above steps on the ladder portion so that the upper handle section may by used to steady a person using the step ladder, thereby allowing the user to safely, even when disposed on the top step. Further, the handle section may be used to support the tray.  
         [0009]     The present invention is a step ladder, including a first ladder frame and a second ladder frame operably pivotably coupled to the first frame intermediate the second ladder frame, the second ladder frame being formed of a unitary loop defining a step portion and a handle section, the step portion and a handle section being coupled a first bend and a second generally reverse bend. The present invention is further a method of forming a step ladder. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is a side view of a step ladder with ladder portion and a utility tray according to the present invention where the ladder portion is in an open position and the utility tray is in an extended position.  
         [0011]      FIG. 2  is a perspective view of the step ladder where the ladder portion is in the open utility tray position and in a storage position.  
         [0012]      FIG. 3  is a front view of the step ladder where the ladder portion is in a closed position and the utility tray is in the storage position.  
         [0013]      FIG. 4  is an enlarged view of an upper surface of the utility tray.  
         [0014]      FIG. 5  is an enlarged view of a lower surface of the utility tray.  
         [0015]      FIG. 6  is an enlarged side view of the utility tray in the extended position.  
         [0016]      FIG. 7  is an enlarged side view of a slide track on the utility tray.  
         [0017]      FIG. 8  is an enlarged side view of the slide track where the utility tray is in a partially lowered position.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0018]     The present invention is a step ladder  10  having a ladder portion  12  and a utility tray  14 , as illustrated in  FIGS. 1-3 . The ladder portion  12  includes a first frame  16  that is pivotally attached to second frame  18 . The utility tray  14  is pivotable with respect to the ladder portion  12  between a generally horizontal extended position, as illustrated in  FIG. 1 , and a generally vertical storage position, as illustrated in  FIGS. 2 and 3 . The utility tray  14  is generally positioned in the frame  18  when the utility tray  14  is in the vertical storage position.  
         [0019]     With the utility tray  14  in the extended position, tools and other objects placed on the utility tray  14  may be easily and conveniently reached when the step ladder  10  is in use without interfering with the ability of a person to access the ladder portion  12 . Alternatively, when the utility tray  14  is pivoted to the storage position, the step ladder  10  may be placed adjacent a wall or other similar structure.  
         [0020]     The second frame  18  has a pair of side posts  20  and an upper handle section  22  that extends between the pair of side posts  20 . The upper handle section  22  extends sufficiently above steps on the ladder portion  12  so that the upper handle section  22  may by used to steady a person using the step ladder  10 .  
         [0021]     A first step  24  is operably connected to the first frame  16  and the second frame  18 . The first step  24  pivots between an extended position and a retracted position as the step ladder  10  is moved from an open position, as illustrated in  FIGS. 1 and 2 , and a closed position, as illustrated in  FIG. 3 . The first step  24  pivots with respect to at least one of the first frame  16  and the second frame  18  as the first frame  16  is pivoted with respect to the second frame  18 . A second step  25  is preferably operably connected to the first frame  16  and the second frame  18 . The second step  25  pivots with respect to the second frame  18 .  
         [0022]     Each of the steps  24 ,  25  has a pair of opposed side surfaces  30 . Proximate a front end of the side surfaces  30 , each of the steps  24 ,  25  is pivotally attached to the side posts  20 . Proximate a back end of the side surfaces  30 , each of the steps  24 ,  25  is interconnected with a tie bar  32 . This configuration permits each of the steps  24 ,  25  to pivot in unison.  
         [0023]     A support bar (not shown) is provided at an intermediate location on the first frame  16 . When the step ladder  10  is in the extended position, the first step  24  rests on the support bar to thereby maintain the first step  24  in a substantially horizontal position.  
         [0024]     A linkage bar  36  preferably extends between the first frame  16  and the tie bar  32 . The linkage bar  36  is preferably attached to a lower portion of the first frame  16 . The linkage bar  36  is preferably attached to an intermediate location on the tie bar  32 .  
         [0025]     The linkage bar  36  causes the first frame  16  to pivot towards the second frame  18  as the first step  24  is pivoted from a substantially horizontal orientation to a vertical orientation. The linkage bar  36  is preferably pivotally attached to the tie bar  32  proximate to where the tie bar  32  attaches to the second step  25 .  
         [0026]     A lock mechanism  44  is preferably attached to the first step  24 . The lock mechanism  44  is preferably an L shaped piece that is pivotally mounted to the first step  24 . An end of the lock mechanism  44  engages the support bar  36  and thereby retains the step ladder  10  in the opened position.  
         [0027]     The lock mechanism  44  increases the stability of the step ladder  10  by preventing premature folding from the opened position to the closed position. The lock mechanism  44  operates to easily lock the step ladder  10  in the opened position while providing a valuable safety feature that reduces the likelihood of injury to the step ladder user.  
         [0028]     The utility tray  14  has a front end  50  and a rear end  52 , as mostly clearly illustrated in  FIGS. 4-7 . The utility tray  14  is pivotally attached to the second frame  18  proximate the front end  50 . A pair of support arms  54  supports the rear end  52 . One of the support arms  54  is preferably located on each side panel  55  of the utility tray  14 .  
         [0029]     Each side panel  55  of the utility tray  14  preferably has a slot  56  formed  15  therein, as most clearly illustrated in  FIGS. 6-8 . The slot  56  is generally oriented from the rear end  52  to the front end  50 . Proximate a rear end of the slot  56 , a detent  60  is provided. An upper end of the support arms  54  at least partially seats in the detent  60  to retain the utility tray  14  in the extended position. As most clearly illustrated in  FIG. 9 , the detent  60  is preferably oriented at an angle of less than 90 degrees with respect to the slot  56  so that the detent  60  and the slot  56  form a V shape.  
         [0030]     When it is desired to move the utility tray  14  from the extended position to the storage position, the rear end  52  is raised slightly so that the support arms  54  move out of the detent  60 . Thereafter, the support arms  54  slide in the slots  56  as the rear end  52  is lowered. Knobs  58  are preferably provided at upper ends of the support arms  54  to facilitate operation of the support arms  54 .  
         [0031]     A first end  61  is proximate to where the support arms  54  pivotally attach to the second frame  18 . An inwardly directed extension  62  is preferably provided proximate the first end  61 . The inwardly directed extension  62  is located at a second end  63  of the support arms  54 . The inwardly directed extension  62  is designed to snugly sit in a recess  64  formed in a side panel  56 . Seating of the inwardly directed extension  62  in the recess  64  facilitates maintaining the utility tray  14  in the storage position.  
         [0032]     An upper surface  70  of the utility tray  14  is preferably configured to receive paint cans, tools and other items, as illustrated in  FIG. 4 . Various sized slots for hand tools may be spaced throughout the utility tray  14 . Additionally, a plurality of shallow circular depressions may be integrally formed with the utility tray  14  designed to receive and stabilize a variety of paint can sizes. This structure thereby facilitates maintaining items in a desired location on the utility tray  14 .  
         [0033]     The ladder portion may be folded into a closed position for transport or storage, as illustrated in  FIG. 3 . With the utility tray  14  and the ladder  12  portion in the closed position, the step ladder  10  may be readily moved from place to place or stored between uses.  
         [0034]     To move the utility tray  14  from its generally horizontal extended position to its upright position, upward pressure  100  is applied to the utility tray  14  to disengage the sliding knobs  68  from the detents  60 . Continuous downward pressure on the sliding knobs  68  causes them to slide within the slots  56  and lowers the utility tray  14  until the securing knobs  68  are fit securely into the recesses  64 .  
         [0035]     In an alternative embodiment, extensions may be operably connected to the first frame  16  and the second frame  18 .  
         [0036]     It is contemplated that features disclosed in this application, as well as those described in the above applications incorporated by reference, can be mixed and matched to suit particular circumstances. Various other modifications and changes will be apparent to those of ordinary skill.