Compact truck tailgate and general purpose utility ladder

An exemplary embodiment sets forth an apparatus, including a non-collapsible single unit stair comprising: a pair of opposing side rails supporting at least a top step and a bottom step; a coupler adapted to couple the apparatus to an edge of a horizontal surface; and a height adjustable user-support arm, coupled to one of the side rails with a rotatable coupling, wherein the user-support arm is moveable between a support position and a storage position.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to ladders, and more particularly to a ladder suitable for use as a ladder for vehicles having a tailgate or flatbed, and as a general purpose free-standing ladder.

2. Related Art

Pickup tailgate-type vehicles, e.g., pickup trucks, sport utility vehicles (SUV), and station wagons, in today's world have become a vehicle of choice for a variety of reasons that were not as apparent in the past. A vehicle with a tailgate was considered a “work” type vehicle used in construction, farming, and industry.

Now there are extended cabs, four-door models with luxurious interiors with many features that were previously only found in fine automobiles. Today's SUVs, vans, station wagons, and pick-up trucks are broadly used for tailgate parties, at car races, ballgames, outdoor concerts, beach parties, and many other outdoor activities in addition to their traditional work-related uses.

Unfortunately, accessing a tailgate or flatbed of a vehicle can be quite an obstacle for many people. A major challenge is accessing the bed of the vehicle. It can be very difficult to reach over the side rails of the bed of a vehicle in order to retrieve an object, or to climb into the truck bed without the aid of a step assembly. It is even more difficult to exit the truck bed, whether a person is carrying something or simply trying to get down, because of the height of the tailgate from the ground.

The use of step assemblies for tailgate access is known in the art. However, conventional step assemblies have various shortcomings that make them an imperfect solution to the problem of tailgate and truck bed access.

Some tailgate step assemblies are mounted permanently to a base on the inside of the tailgate, which always encumbers the tailgate. Users of such tailgate step assemblies often have to exercise additional care not to trip over the permanently mounted assembly. Others are mounted permanently to the outside of the tailgate, which exposes the ladder to damage and theft.

Most tailgates or flatbed type vehicles have a standardized distance from the ground to the tailgate or flatbed of approximately 28 inches, 30 inches, 33 inches, 37 inches, or 49 inches. Some conventional tailgate step assemblies have only a single step, which does little to bridge the height gap from tailgate to ground. Still other tailgate step assemblies have very narrow steps, or steps with large height separations, which are difficult for the elderly or disabled to use, as well as tiring for those using the assembly for an extended period of time. For example, virtually all types of ladders and staircase type assemblies in today's marketplace have a step or rung riser height of 9.5 inches to 12 inches, while typical building staircases have riser heights of around 6 to 8 inches.

Most conventional tailgate step assemblies have no support arms. In tailgate step assemblies that do have support arms, the support arms are very short. Short support arms are essentially useless, particularly when leaving the vehicle bed. Most support arms are not permanently attached to the step assembly, which makes them very easy to forget or misplace.

Still other tailgate step assemblies have many moving parts or are collapsible, which tends to make them less stable and prone to malfunction.

Further, no conventional tailgate step assemblies are useable as free-standing step assemblies. If the user of the tailgate step assembly also needs a ladder or step assembly, for example, at a job site, the user would have to bring an extra ladder for that purpose.

What is needed then is an improved tailgate step assembly that overcomes shortcomings of conventional solutions.

SUMMARY OF THE INVENTION

Accordingly, an exemplary embodiment of the present invention includes a non-collapsible staircase-type step assembly that can be coupled to an outside vertical edge of a tailgate or vehicle flatbed, and that has height adjustable support arms. The step assembly may also have telescoping adjustable feet at the underside of the bottom step. The step assembly can be free-standing with a pair of ladder support legs, designed to steady and position the ladder steps (when in the user open position) in a precise horizontal position ready for use. The ladder support legs may also have telescoping adjustable feet attached to the bottom end of the legs. A pair of wheels or casters at the backside of the siderails at the bottom end of the ladder may allow for easy movement of the ladder in a closed position. When coupled to a tailgate, the ladder may leave the tailgate totally clear and unencumbered. The ladder may be easily removed for its many other diversified uses, and is not limited to just being attached to a tailgate or vehicle flatbed.

Embodiments of the present invention may provide for much safer access to the tailgate of a pickup truck when the tailgate is in the horizontal open position and/or the flatbed of a vehicle. With an exemplary riser height of 7 to 8 inches, embodiments of the present invention provide a very uniform standard type design to fit all vehicle tailgate or flatbed configurations.

The user comfort support railings may be permanently attached to the step assembly so they cannot be forgotten or left behind, and may be height adjustable.

In an exemplary embodiment of the present invention, an apparatus may include a non-collapsible single unit stair comprising: a pair of opposing side rails supporting at least a top step and a bottom step; a coupler adapted to couple the apparatus to an edge of a horizontal surface; and a height adjustable user-support arm, coupled to one of the side rails with a rotatable coupling, wherein the user-support arm is moveable between a support position and a storage position.

In one exemplary embodiment of the present invention, the apparatus is coupled to the edge of the horizontal surface, the apparatus does not encumber the horizontal surface substantially.

In one exemplary embodiment of the present invention, the apparatus may further include a second height-adjustable user-support arm.

In one exemplary embodiment of the present invention, the apparatus may further include a pair of support legs, each having a top end coupled with a rotatable leg coupling to a different side rail and a bottom end for resting on a support surface, wherein each support leg is moveable between an extended support position and a folded storage position.

In one exemplary embodiment of the present invention, the support legs are extended, the apparatus is capable of standing freely without being coupled to the horizontal surface.

In one exemplary embodiment of the present invention, the bottom end of each of the pair of support legs further comprises a height-adjustable foot.

In one exemplary embodiment of the present invention, each of the pair of support legs may further include a wheel coupled to the bottom end.

In one exemplary embodiment of the present invention, the apparatus is storable against a vertical surface.

In one exemplary embodiment of the present invention, the apparatus may further include a height-adjustable foot coupled to a bottom end of each of the side rails.

In one exemplary embodiment of the present invention, a wheel may be coupled to a bottom end of each of the side rails.

In one exemplary embodiment of the present invention, each step is approximately 15 inches wide.

In one exemplary embodiment of the present invention, each step is separated vertically from an adjacent step by approximately 7 to 8 inches.

In one exemplary embodiment of the present invention, the user-support arm is adjustable from a height of approximately 15 inches to a height of approximately 32 inches above the top step.

In one exemplary embodiment of the present invention, the apparatus may further include a utility tray coupled to the two user-support arms.

In one exemplary embodiment of the present invention, the coupler may include a fastening slot adapted to receive a bolt head extending from the edge of the horizontal surface.

In one exemplary embodiment of the present invention, the fastening slot may be disposed in the user-support arm, or top step.

In one exemplary embodiment of the present invention, the rotatable leg coupling may include: a pair of rotor limiting plates separated by a separation sleeve, each rotor-limiting plate having a user-ready slot and a storage slot in an outer edge, wherein an outer side of one rotor limiting plate is coupled to the side rail and an outer side of the other rotor limiting plate is coupled to the support leg; fastening means disposed substantially within the separation sleeve to fasten the pair of rotor limiting plates to each other, wherein the fastening means forms a pivot point for the support leg; a locking pin coupled to the support leg and adapted to fit in the user-ready and the storage slots; and tension adjusting means adapted to allow the locking pin to move radially inward and outward with respect to the pivot point.

In one exemplary embodiment of the present invention, the rotatable coupling may include a pair of rotor limiting plates separated by a separation sleeve, each rotor limiting plate having a user-ready slot and a storage slot in an outer edge, wherein an outer side of one rotor limiting plate is coupled to the side rail and an outer side of the other rotor limiting plate is coupled to the user-support arm; fastening means disposed substantially within the separation sleeve to fasten the pair of rotor limiting plates to each other, wherein the fastening means forms a pivot point for the user-support arm; a locking pin coupled to the user-support arm and adapted to fit in the user-ready and the storage slots; and tension adjusting means adapted to allow the locking pin to move radially inward and outward with respect to the pivot point.

In another exemplary embodiment of the present invention, a rotatable coupling may include: a pair of rotor limiting plates separated by a separation sleeve, each rotor limiting plate having a user-ready slot and a storage slot in an outer edge, wherein an outer side of one rotor limiting plate is adapted to be coupled to a fixed support and an outer side of the other rotor limiting plate is adapted to be coupled to a rotatable member; fastening means disposed substantially within the separation sleeve to fasten the pair of rotor limiting plates to each other, wherein the fastening means forms a pivot point for the rotatable member; a locking pin coupled to the rotatable member and adapted to fit in the user-ready and the storage slots; and tension adjusting means adapted to allow the locking pin to move radially inward and outward with respect to the pivot point.

In one exemplary embodiment of the present invention, the tension adjusting means may include a spring coupled at one end to the separation sleeve and at the opposite end to the locking pin.

In one exemplary embodiment of the present invention, the tension adjusting means may include: a spring adapted to be coupled at one end to the fixed support and at the opposite end to the rotatable member.

In one exemplary embodiment of the present invention, the rotatable coupling may include a curved slot disposed in said side rail; a rotation rivet coupled to said user support arm and disposed in said curved slot, adapted to move freely in said curved slot; a coupling adapted to couple said user-support arm to said side rail and to allow said user-support arm to rotate between said support position and said storage position; and means for preventing said user-support arm from moving when in said support position or said storage position.

An exemplary embodiment of the invention is discussed in detail below. While specific exemplary embodiments are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations can be used without parting from the spirit and scope of the invention.

FIG. 1depicts a side view of a first exemplary embodiment of non-collapsible staircase-type ladder1. The ladder1may include a non-collapsible single unit stair that may include a pair of opposing side rails5supporting four steps6. Although the side rails5and steps6are discussed as separate components, exemplary embodiments of the present invention may comprise a single unit of side rails5and steps6, formed, for example, from a single molded piece of plastic, fiberglass, aluminum plate, diamond plate, or stainless steel plate, etc., forming the side rails and steps. The ladder1may further include a pair of support legs12, and one or two telescoping user-support arms16. The stability of ladder1may be improved with a collapsible cross-brace15which may be coupled to side rail5and support leg12.

The ladder1may be coupled to the outermost edge3of an open truck tailgate4. The coupling mechanism may include, for example, tailgate-to-ladder fastening bolts25that may protrude from edge3of the tailgate4. SeeFIGS. 4 and 5below. Slots (not shown inFIG. 1, but see slots17,10described further below with reference toFIGS. 3 and 6, respectively) may be provided in, e.g., the user-support arms16, or in the back of the top step6, that may be operative to slide over the fastening bolts25and secure the ladder1to the tailgate edge3. In this first embodiment, when the tailgate4is secured to slots in the back of the top step of the ladder1, the top step may be at the same elevation as the open tailgate4. The fastening bolts25may move freely up and down while positioned in the slots, while the ladder1may stay immobile on the ground. Coupling the ladder1to the edge3of a tailgate4may leave the horizontal surface of the tailgate4unencumbered for access of people or materials. The user-support arm16and support leg12are also shown in a storage position on the outside of side rail5, for reference.

When ladder1is in the access user ready position, as shown inFIG. 1, the slots may be centered at the same center as fastening bolts25when tailgate4is in the open horizontal position. In an exemplary embodiment, to achieve this alignment, for example, on uneven ground, the ends of the support legs12may be equipped with adjustable telescopic feet13, and the inside face of the side rails5or the inside front face of the bottom step6may be equipped with adjustable telescopic feet8. In an exemplary embodiment, the casters14may be installed on an outside bottom surface of the side rails5to allow the ladder1to be rolled about in a closed position.

FIG. 2depicts an exemplary side view of ladder1in a free-standing, user-ready position, with telescoping user-support arms16fully extended, according to an exemplary embodiment. A utility tray20may be coupled to the upper ends of user-support arms16and ready for use. Height-adjustable feet8and13together may permit ladder1to be leveled when open on an uneven surface. In addition, in an exemplary embodiment, spring-actuated casters19may be coupled to the lower ends of support legs12or on the inside face of side rails5, or on the inside front face of bottom step6. In an exemplary embodiment, casters19may permit the operator to roll ladder1from one area to another without having to open and close ladder1. This feature may be useful for trades people using the ladder in areas where the ladder may roll easily on the floor. The feature also makes it possible to move the ladder with any tools and supplies in use aboard the ladder without having to fold and carry the ladder and find another means for moving the tools and supplies. Support leg12is also shown in a storage position underneath steps6.

FIG. 2Adepicts an exemplary side view of ladder1in a free-standing, user-ready position, with user-support arms16in a storage position, where they can be mounted to an outside face of the side rails5, which permits use of the ladder without the user-support arms16. Support leg12is also show in a storage position against the outside of side rail5.

FIG. 3depicts a front view of ladder1. Ladder1may provide a large opening23in the stair risers, which may allow the user's entire foot, or both feet, to be on one step6. In an exemplary embodiment, each step may be about fifteen inches wide and may be about 9 inches deep. In an exemplary embodiment, each step may be vertically separated from an adjacent step by about seven to eight inches. In an exemplary embodiment, height-adjustable feet13may be attached to support leg12by matching up holes in leg12with holes on an insert piece on height-adjustable foot13. Feet8may be adjusted by matching up holes in a foot8with holes on an insert piece, and by the insertion of a dimpled locking spring device30. The insert piece may be on the inside face of the bottom step6or on the inside face of side rails5. Foot8may be adjusted and secured at a desired position. The height of user-support arm16may be adjusted in a similar manner, or by any other securable, adjustable means. Slots10are indicated where they may be positioned, e.g., in the back of the top step6. Slots17are shown in the back of user-support arms16, although slots17may not be visible from the front of ladder1. The use of slots10or slots17depends on the alignment of the tailgate or flatbed with the ladder. For example, if the tailgate or flat bed is higher than the top step6, then slots17are used. If the tailgate or flatbed is at the same height as the top step6, then slots10are used.

FIG. 4depicts an exemplary top view of a top step of an exemplary embodiment of the present invention where the ladder may be attached to the tailgate from the user-support arms16. The ladder1may be coupled to the vertical face3of tailgate4, for example, by sliding slots17, disposed in user-support arms16, over tailgate-to-ladder fastening bolts25protruding from the vertical face3of open tailgate4, or of a vehicle flatbed.

FIG. 5depicts an exemplary top view of a top step of an embodiment of the present invention where the ladder may attach to the vertical face3of the open tailgate from the vertical backdrop behind the top step6. Slots10may be disposed in the back of the top step that may be adapted to slide over fastening bolts25.

FIG. 6depicts an isometric view of the ladder shown inFIG. 1, secured to an outside face3of a tailgate4in the horizontal position, by fastening means which may be provided in the vertical back drop behind the top step6. Fastening the ladder1to the tailgate4at the top step may allow the top step to be substantially level with the horizontal tailgate.

FIG. 7depicts a side view of the ladder coupled to a tailgate, with fastening means provided in the user-support arms16, where the tailgate is higher than the top step of the ladder.

FIG. 8depicts a side view of the ladder secured to an exemplary flatbed trailer9with fastening means provided in the user-support arms16. The fastening means may be, for example, bolts or other means described in relation toFIG. 4, or any of various conventional couplers, fasteners, or connectors. When the ladder is fastened by the user-support arms16, the top step of the ladder may be positioned one step-height below the flatbed or tailgate height.

FIG. 9depicts an exemplary front view of a ladder100secured to the furthest outside vertical section of the deck at the emergency door exit of a school bus type vehicle. The user-support arms16are shown stowed in a storage position.

FIG. 10depicts an exemplary side view of an exemplary five-step embodiment102of the staircase type ladder in an open position which may be secured or standing adjacent to the bed of an enclosed tractor trailer like vehicle. Also shown is the staircase type ladder102in a storage position under the bed of the trailer.

FIG. 11depicts a top view of ladder1which may be mounted to the inside of a closed truck tailgate in the concealed storage position. User-support arm16and support leg12are shown in a storage position on the outside face of side rail5.FIG. 12depicts an exemplary side view of the stored ladder shown inFIG. 11. The folded ladder assembly may be mounted, for example, by means of retractable storage brackets7coupled to the outer face3of tailgate4via fastening bolts25.

FIGS. 13–15show various exemplary views of a first exemplary embodiment of a rotatable coupling200that may be used to couple support leg12or user-support arm16to an exemplary ladder according to embodiments of the present invention. Hereinafter, the coupling may be described as being attached to support leg12, however, the coupling may be coupled analogously to user-support arm16, as shown, for example, inFIG. 14.

Support leg12may be mounted in between rotor limiting plates36. Each rotor limiting plate36may have at least two slots disposed in its outer edge: a storage slot31,43, and a user-ready slot38. The couplings shown inFIGS. 13 and 14are substantially similar, however, the separation and angle between the user-ready slot and storage slot in a support leg coupling may be different from the separation and angle in a user-support arm coupling. Although only two slots are described in detail below, any number of slots could be provided in the rotor limiting plates36to allow more flexibility in positioning the support legs12and the user-support arms16. Rotor limiting plates36may be substantially semi-circular, or circular less a sector as illustrated, but are not limited to that shape.

A separation sleeve41may be placed between rotor limiting plates36and over a securing bolt32. Separation sleeve41may be long enough to permit rotation of support leg12about separation sleeve41. Support leg12may have a locking pin34mounted inside a hollow stanchion of support leg12that may penetrate the walls of support leg12. Locking pin34may protrude from the outside face of support leg12for a length approximately equal to the thickness of the rotor limiting plate36.

One end of a spring33may be coupled to locking pin34, while the opposite end of spring33may be coupled to separation sleeve41in between rotor limiting plates36. Spring33may be generally stretched and under tension at all times, resulting in locking pin34being held against the bottom of one of the user-ready or storage slots, as seen, e.g., inFIG. 13, or may be held against the outer edge of rotor limiting plates36, as seen, e.g., inFIG. 14.

When locking pin34is in a slot, e.g., slot38, a gap may be created between the bottom of contoured spring slot40, and the bottom of separation sleeve41. This gap may be approximately equal to the diameter of stationary locking pin34. When the user desires to move support leg12, or user-support arm16, from one position to another, support leg12may be pulled such that locking pin34comes out of the slot where it rests. While locking pin34is out of its current slot, support leg12may be rotated to another slot while locking pin34slides along the outer edge of rotor-limiting plates36. Pulling support leg12to remove locking pin34from a slot temporarily closes the gap.

FIGS. 17–19show how various exemplary views of second exemplary embodiment of a rotatable coupling300that may be used to couple support leg12or user-support arm16to an exemplary ladder according to embodiments of the present invention. Hereinafter, the coupling is described as being attached to support leg12, however, the coupling300may be coupled analogously to user-support arm16, as shown, for example, inFIG. 18.

Support leg12may be coupled to a rotary plate45secured in between rotor limiting plates36. A spring33may be secured at one end to support leg12, for example, in a hole47. The other end of spring33may be secured to rotor limiting plate36, for example, in a hole46. A configured slot44in rotary plate45may provide a gap between the bottom of the separation sleeve41and the bottom of the configured slot44approximately equal to the diameter of locking pin48. This gap may permit locking pin48to move to the outside edge of rotor limiting plates36when more pressure is applied to spring33, e.g., when support leg12is pulled on in the direction of the line of spring33.

FIG. 16shows an isometric view of part of an exemplary embodiment of the present invention, with user-support arm16secured to an outside face side rail5with rotatable coupling200. Further, support leg12is shown secured to the inside face of side rail5with rotatable coupling200. Support legs12may also be secured to the outside face of side rails5at a point just below user-support arms16. User-support arm16and support leg12may be rotated from a user ready slot to a storage position slot or vice versa. Either of the embodiments shown inFIGS. 13–15orFIGS. 17–19may be used to couple support legs12or user-support arms16to the ladder1. Additionally, other coupling mechanisms may also be used.FIG. 20is analogous toFIG. 16, but for rotatable coupling300.

FIG. 21shows an isometric view of a one-piece non-collapsible single-unit stair, without any additional components. The stair may be made in a mesh style, or solid. The stair may be made from, e.g., aluminum, diamond plate, stainless steel, fiberglass, nylon or plastic, formed or stamped from a one piece configuration. The steps of the stair may be perforated to prevent liquids from pooling on the steps. The steps may also have a non-skid surface.

FIG. 22depicts a rear view showing the back side of the top step6. The rotatable couplings200and300, respectively, on the user-support arms16are shown coupled to the outside face of side rails5, while the rotatable couplings200and300for the support legs12may be coupled to the inside face of side rails5. The rotatable couplings for the support leg12may be coupled in the alternative to the outside face of side rails5.

FIG. 23depicts a side view of a third exemplary embodiment of a rotatable coupling used to couple a user-support arm16to the side rail5.FIG. 23Ais an enlarged view of the rotatable coupling shown inFIG. 23.FIGS. 23 and 23Ashow the user-support arm in the user ready and storage positions. The user-support arm16is pulled against the outside face of side rail5by a rotation rivet37that holds user-support arm16and side rail5together. User-support arm16may also be held in position with a rivet26, whose shaft may pass through user-support arm16and curved slot39. Slot39may be wide enough to permit penetration of the shaft of rivet26. Rivet26may be disposed in a hole27in user-support arm16. The shaft of rivet26may be long enough to extend from the outside face of user-support arm16to the inside face of slot39in side rail5. The disposition of rivet26in slot39may permit the rotation of user-support arm16between a user-ready and a storage position. User-support arm16may be secured in position to side rail5by a thumbscrew35through a hole50(user ready position) or hole51(storage position), both in side rail5. When in the storage position, user-support arm16may be further secured with a holding bracket24coupled to side rail5.

FIG. 24depicts a back view of the user-support arm16in a user ready position and secured to the outside face of side rail5. Hole50in side rail5receives thumbscrew35to secure user-support arm16. The shaft of rivet26fits within slot39, and is held in slot39by the ends of the rivet26.