Scaffold plank with end connector and method of making the same

A scaffold plank assembly for engagement to a scaffolding frame. The scaffold plank assembly comprises an elongate, non-metal plank defining opposed first and second ends and at least one interior cavity. Attached to respective ones of the opposed ends of the plank is a pair of end connectors. Each of the end connectors comprises a main body defining an arcuate body engagement surface, and at least two arms which are attached to the main body. Each of the arms also defines an arcuate arm engagement surface which is substantially continuous with the body engagement surface. Attached to and extending from the main body is at least one attachment finger which is extensible into the interior cavity of the plank. The body and arm engagement surfaces are sized and configured to be cooperatively engageable to the scaffolding frame.

Not Applicable

BACKGROUND OF THE INVENTION

The present invention relates generally to scaffolding systems, and more particularly to a scaffold plank fabricated from a plastic material and optionally including end connectors which are configured to facilitate the firm engagement of the plank to a support frame structure.

As is well known in the building industry, scaffolding is virtually always employed during various facets of exterior and/or interior building construction or refurbishment. Known scaffolding systems typically comprise steel support frame structures which are selectively engageable to each other in a stacked fashion for achieving a desired overall height. In addition to the support frame structures, the scaffolding system includes a multiplicity of elongate scaffold planks, each of which is horizontally extensible between a respective pair of the support frame structures. The prior art scaffold planks are most typically fabricated from wood. Indeed, the use of wood for the prior art scaffold planks has been a long standing tradition in the building industry

Though wood scaffold planks have been and continue to be generally suitable for use in scaffolding systems, the use of wood for the scaffolding planks gives rise to certain shortcomings and deficiencies which detract from their overall utility. More particularly, scaffold planks fabricated from wood are susceptible to splitting as well as to dry rot. Additionally, when exteriorly used scaffolding systems are subjected to rain or thunder storms as often occurs, the resultant water soaking of the wood scaffold planks virtually doubles their weight as compared to when dry, thus substantially increasing the difficulty by which they are moved or otherwise manipulated. Such water soaking of the wood scaffold planks also often results in the warping or twisting thereof. As will be recognized, due to their susceptibility to splitting, dry rot and warping/twisting, the prior art wood scaffold planks have a reasonably limited life span and require moderately frequent replacement.

Another drawback associated with the use of wood scaffold planks is the common occurrence of scaffold setters experiencing splinters in their hands when working with the same. Indeed, occurrences of splinters can reach a level of severity resulting in the initiation of a workers compensation claim. Moreover, because nails are also often used in conjunction with wood scaffold planks, workers are more susceptible to being injured by nails which are left there within.

A further problem associated with the use of wood scaffold planks is the relatively high cost thereof attributable to diminishing supplies of lumber. Indeed, ongoing extensive worldwide deforestation and the related environmental and ecological problems has, in addition to resulting in increases in the price of lumber, stimulated a movement to adopt lumber alternatives for purposes of contributing to the conservation and restoration of forests. These diminishing supplies of lumber also frequently give rise to delays in the delivery of lumber raw material to those mills which manufacture wood scaffold planks, thus resulting in periodic problems in meeting the supply demands of the building industry. Though metal (e.g., aluminum) scaffold planks have been developed in the prior art as an alternative to wood planks, such aluminum planks are extremely costly. Additionally, both the wood and aluminum scaffold planks of currently known scaffolding systems lack connectors which are suited to allow the plank to be quickly and easily engaged to a support frame structure.

The present invention addresses these concerns by providing a scaffold plank which is manufactured or fabricated from a plastic material and may optionally be provided with end connectors which are specifically sized and configured to facilitate the quick and easy interface of the plank to a scaffolding system support frame structure. As will be discussed below, the plastic scaffold plank of the present invention, though possessing the same level of structural integrity or rigidity as the prior art wood scaffold planks, does not have the same susceptibility to splitting, dry rot or warping/twisting. Additionally, the weight of the scaffold plank of the present invention is the same whether wet or dry. The use of plastic for the scaffold planks of the present invention also eliminates occurrences of splinters, and substantially eliminates injuries potentially caused by nails left therein. Further, since the scaffold planks of the present invention may be fabricated from recycled/recyclable plastic material, they address the need of recycling used plastic into a useful product, in addition to satisfying the increasing desire in industry for lumber alternatives. These, and other features of the present invention will be described in more detail below.

BRIEF SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a scaffold plank assembly for engagement to a scaffolding frame. The scaffold plank assembly comprises an elongate, non-metal plank which defines opposed first and second ends and at least one interior cavity. Attached to respective ones of the opposed ends of the plank is a pair of end connectors. The end connectors each comprise a main body defining an arcuate engagement surface, and at least two arms which are attached to the main body. Each of the arms defines an arcuate engagement surface which is substantially continuous with the body engagement surface. Attached to and extending from the main body is at least one attachment finger which is extensible into the interior cavity of the plank. The body and arm engagement surfaces are sized and configured to be cooperatively engageable to the scaffolding frame.

In addition to the arcuate body engagement surface, the main body includes at least two notches formed therein. The notches are sized and configured to receive respective ones of the arms of another end connector in a nesting fashion, thus allowing the end connectors of two adjacent scaffold planks to be cooperatively engaged to a common support bar of the scaffolding frame.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same,FIG. 1perspectively illustrates a scaffold plank10constructed in accordance with a first embodiment of the present invention. The scaffold plank10has an elongate, generally rectangular configuration and includes a main body12which defines opposed ends. Attached to the respective ones of the opposed ends of the main body12is a pair of identically configured end caps14, the precise structural attributes of which will be described in more detail below. In the first embodiment, the preferred height or thickness of the scaffold plank10is in the range of from about 1.0 inch to about 2.50 inches, and is preferably about 1.50 inches. The preferred width of the scaffold plank10is in the range of from about 6.0 inches to about 15.0 inches, and is preferably about 9.50 inches. The overall length of the scaffold plank10(including the main body12and end caps14) is variable. In this respect, it is contemplated that the scaffold plank10may be provided to have an overall length of either 6 feet, 9 feet, 12 feet, or 16 feet. However, those of ordinary skill in the art will recognize that the scaffold plank10of the present invention may be fabricated to have length, width, and/or height dimensions differing from those described above.

As seen inFIGS. 1 and 1A, the scaffold plank10may be provided with two pairs of pre-formed nail holes16, with each pair of the nail holes16being disposed within the body12in relative close proximity to a respective one of the end caps14. In addition to the nail holes16, the main body12of the scaffold plank may be formed to include a spaced pair of arcuately contoured, concave frame setting notches18in the underside or bottom surface20thereof. As will be described in more detail below, the nail holes16and/or frame setting notches18, if included, are preferably formed in the main body12via finishing operations conducted subsequent to the fabrication of the main body12. The nail holes16and/or frame setting notches18are used to facilitate the engagement or interface of the scaffold plank10to a conventional steel frame support structure of a scaffolding system.

Referring now toFIGS. 2 and 2A, the main body12of the scaffold plank10itself comprises a top wall22which defines a top surface24, a bottom wall26which defines the bottom surface20, and an opposed pair of longitudinally extending sidewalls28which are integrally connected to the top and bottom walls22,26. Integrally connected to and extending perpendicularly between the top and bottom walls22,26, and in particular the inner surfaces thereof, are five (5) reinforcement webs30. The reinforcement webs30extend in generally parallel relation to each other, thus defining six (6) compartments of cavities which extend longitudinally within the interior of the main body12. In the scaffold plank10, the preferred thickness of the top, bottom and sidewalls22,26,28and reinforcement webs30is approximately 0.1875 inches.

As further seen inFIG. 2, formed on the inner surface of the top wall22and extending longitudinally therealong in spaced, generally parallel relation to each other are seven (7) ribs32. Similarly, formed on and extending longitudinally along the inner surface of the bottom wall26in spaced, generally parallel relation to each other are seven (7) ribs34which are disposed in opposed, aligned relation to respective ones of the ribs32. The ribs32,34extend generally perpendicularly from the inner surfaces of the top and bottom walls22,26, respectively. In the scaffold plank10, the top, bottom and sidewalls22,26,28and ribs32,34extending within the outermost pair of cavities collectively form a pair of slots which are each adapted to accommodate an elongate, rectangularly configured reinforcement bar36. The centermost pair of ribs32,34, top and bottom walls22,26, and centermost reinforcement web30also collectively define a slot which is adapted to accommodate a third reinforcement bar36. The four remaining ribs32and four remaining ribs34collectively define two more slots which extend within respective ones of those cavities disposed adjacent the outermost pair and are adapted to accommodate two additional reinforcement bars36. In the scaffold plank10, the reinforcement bars36are each preferably fabricated from steel having a thickness of approximately 0.1875 inches.

In the scaffold plank10shown inFIG. 2, three (3) reinforcement bars36are depicted as being disposed within respective ones of the five (5) slots extending within the interior of the main body12. Those of ordinary skill in the art will recognize that no reinforcement bars36need to be provided within the main body12, and that less than three or up to five reinforcement bars36may be included therein. The number of reinforcement bars36, if any, included in the interior of the main body12of the scaffold plank10is dependent upon the level of structural integrity or rigidity desired in relation thereto. In the scaffold plank10, each of the reinforcement bars36is preferably sized such that when disposed within the interior of the main body12in the above-described manner, the opposed ends thereof do not protrude beyond respective ones of the opposed ends of the main body12.

As indicated above, in addition to the main body12, the scaffold plank10includes the end caps14which are attached to respective ones of the opposed ends of the main body12. As seen inFIGS. 2 and 2A, each of the end caps14has a generally rectangular configuration, and includes an outer surface38which defines a pair of beveled or concave corner regions adjacent respective ones of the lateral sides thereof. In addition to the outer surface38, each end cap14has an inner surface40which includes an elongate channel42formed therein. The channel42is formed within each end cap14for purposes of reducing the overall weight thereof. As seen inFIG. 2, the channel42terminates inwardly of the lateral sides of the end cap14.

Formed on the inner surface40of each end cap14are a total of eight (8) rectangularly configured attachment tabs44. The attachment tabs44are arranged in two sets of four, with the attachment tabs44of each set being disposed in spaced relation to each other along a respective one of the longitudinal sides of the channel42. Additionally, the attachment tabs44of one set are disposed in opposed, linear alignment with respective ones of the attachment tabs44of the other set. Importantly, the attachment tabs44are oriented so as to be advanceable into respective ones of the cavities defined within the main body12and not interfere with any of the reinforcement webs30thereof. In this respect, the attachment tabs44are sized and configured such that when each opposed pair thereof is received into a respective one of the cavities of the main body12, those edges of the attachment tabs44disposed furthest from the channel42are in abutting contact with the inner surfaces of respective ones of the top and bottom walls22,26of the main body12. Those of ordinary skill in the art will recognize that different numbers of attachment tabs44arranged in alternative patterns are contemplated in relation to the end caps14. In the scaffold plank10, each of the end caps14may be sonically welded to the main body12, or may alternatively be attached to the main body12through the use of fasteners such as pins, snap fit, or an adhesive. However, those of ordinary skill in the art will recognize that other methods may be employed to facilitate the attachment of the end caps14to the main body12. As is seen inFIG. 1, the end caps14are sized relative to the main body12such that when attached thereto, the longitudinal sides of the end caps14are substantially flush with the bottom surface20of the bottom wall26and top surface24of the top wall22, with the lateral sides of the end caps14being substantially flush with respective ones of the outer surfaces of the sidewalls28.

Both the main body12and end caps14of the scaffold plank10are preferably fabricated from a plastic material. A preferred plastic material is a ten percent to fifty percent glass-filled polypropylene/nylon blend. Such plastic material may alternatively comprise either virgin or recycled plastic. It is contemplated that the plastic or nylon material may be filled with either glass or another suitable reinforcement material to increase the structural integrity/rigidity thereof. Those of ordinary skill in the art will further recognize that the main body12and end caps14need not necessarily be fabricated from identical materials. In this respect, each of the end caps14could be fabricated from a metallic material such as aluminum. As indicated above, each of the reinforcement bars36is preferably fabricated from steel.

Additionally, the main body12of the scaffold plank10is preferably fabricated via an extrusion process. If one or more reinforcement bars36is to be included within the interior of the main body12, it is preferred that the plastic material used to form the main body12will be extruded about the reinforcement bar(s)36. However, those of ordinary skill in the art will recognize that the reinforcement bars36may be inserted into the interior of the main body12via a separate procedure which is conducted subsequent to the formation of the main body12via the extrusion process. The end caps14are preferably fabricated through the use of an injection molding or vacuum forming process and, as indicated above, secured to respective ones of the opposed ends of the main body12subsequent to the fabrication of the same.

Subsequent to the fabrication of the main body12via the extrusion process, it is contemplated that the nail holes16may be formed therein via a follow-up drilling operation. Additionally, the frame setting notches18may be formed in the bottom surface20via a follow-up grinding or machining operation. Moreover, the top surface24of the top wall22may be subjected to a grinding or machining operation for purposes of applying a texture or roughened feature thereto. Though not shown, it is further contemplated that the cavities defined by the main body12may be filled with structural foam or some equivalent thereto prior to the attachment of the end caps14to the main body12for purposes of increasing the structural strength or rigidity of the completed scaffold plank10.

Referring now toFIGS. 3 and 4, there is depicted a scaffold plank100constructed in accordance with a second embodiment of the present invention. The scaffold plank100also has an elongate, generally rectangular configuration and includes a main body having a top wall104which defines a top surface106, an opposed pair of longitudinally extending sidewalls108which are integrally connected to the top wall104, and an opposed pair of end walls110which are integrally connected to the top and sidewalls104,108and define respective ones of the opposed ends of the scaffold plank100. Though the scaffold plank100of the second embodiment preferably does not include the previously described end caps14since the opposed ends thereof are defined by the end walls100of the main body102, those of ordinary skill in the art will recognize that such end caps14may be employed as an alternative to the integrally formed end walls100. Similar to the configuration of the outer surfaces38of the end caps14, the end walls110of the main body102may be formed to include beveled corner regions adjacent respective ones of the sidewalls108.

As is seen inFIGS. 3 and 4, the main body102of the scaffold plank100is formed to include four (4) channel members112which are integrally connected to the inner surface of the top wall104and extend longitudinally therealong in spaced, generally parallel relation to each other. The outermost pair of channel members112each have a generally L-shaped configuration and, in addition to being integrally connected to the inner surface of the top wall104, are integrally connected to the inner surfaces of respective ones of the sidewalls108. The central two channel members112each have a generally U-shaped configuration and are integrally connected to only the inner surface of the top wall104. In the scaffold plank100, the outermost pair of channel members112and inner surfaces of the top sidewalls104,108collectively define a pair of slots, with another pair of slots being collectively defined by the central two channel members112and inner surface of the top wall104. Each of these four (4) slots has a generally rectangular configuration and extends substantially along the length of the main body102. Additionally, each of these slots is sized and configured to accommodate a reinforcement bar114which is identically configured to the previously described reinforcement bar36and preferably fabricated from steel.

In addition to the channel members112, integrally connected to and extending perpendicularly from the inner surface of the top wall104are three (3) longitudinally extending primary reinforcement webs116. In the scaffold plank100, each of the primary reinforcement webs116is disposed equidistantly between an adjacent pair of channel members112and extends in generally parallel relation thereto. Integrally connected to and extending angularly between each of the primary reinforcement webs116and the channel members112of the corresponding pair are a plurality of secondary reinforcement webs118which are also integrally connected to the inner surface of the top wall104and extend generally perpendicularly relative thereto. As is best seen inFIG. 4, the channel members112and primary and secondary reinforcement webs116,118are each sized and configured such that the distal surfaces thereof (i.e., those surfaces disposed furthest from the inner surface of the top wall104) and are oriented inwardly from the distal edges of the sidewalls108and end walls110(or end caps14) of the main body102. In this respect, the distal edges of the side and end walls108,110of the main body102protrude slightly outwardly from the distal surfaces of the channel members112and primary and secondary reinforcement webs116,118for reasons which will be described in more detail below.

In addition to the main body102, the scaffold plank100of the second embodiment may comprise a cover member120which also has an elongate, generally rectangular configuration and define opposed, generally planar surfaces. In the scaffold plank100, the cover member120is attached to the main body102such that the inner surface of the cover member120lies in abutting contact with the distal surfaces of the channel members112and primary and secondary reinforcements webs116,118. In this respect, the length and width dimensions of the cover member120are slightly smaller than those of the main body102such that when the inner surface of the cover member120is placed in abutting contact with the channel members112and primary and secondary reinforcement webs116,118in the aforementioned manner, the outer surface of the cover member120is substantially flush or continuous with distal edges of the side and end walls108,110of the main body102.

The attachment of the cover member120to the main body102is preferably facilitated through the use of sonic welding, pins, or an adhesive. However, those of ordinary skill in the art will recognize that other methods may be employed to facilitate the attachment of the cover member120to the main body102. Since the cover member120, when attached to the main body102, does not protrude beyond the side and end walls108,110of the main body102, the overall length, width and height dimensions of the scaffold plank100are governed by the main body102thereof. Though not shown, it is contemplated that a sealing strip will be compressed between the cover member120and the main body102when the cover member120is attached to the main body102.

In the second embodiment, the preferred height or thickness of the main body102, and hence the scaffold plank100, is in the range of from about 1.0 inch to about 2.50 inches, and preferably about 1.50 inches. The preferred width of the main body102is in the range of from about 6.0 inches to about 15.0 inches, and is preferably about 9.50 inches. The overall length of the main body102is variable, with it being contemplated that the same may be provided in lengths of either 6 feet, 9 feet, 12 feet, or 16 feet.

Like the main body12and end caps14of the scaffold plank10of the first embodiment, both the main body102and cover member120of the scaffold plank100of the second embodiment are preferably fabricated from a plastic material. As is the first embodiment, a preferred plastic material is a ten percent to fifty percent glass-filled polypropylene/nylon blend. An alternative plastic material may be either virgin or recycled plastic. It is contemplated that the plastic or nylon material may be filled with either glass or another suitable reinforcement material to increase the structural integrity/rigidity thereof. As indicated above, each of the reinforcement bars114is preferably fabricated from steel. However, the reinforcement bars114as well as the above-described reinforcement bars36may each be fabricated from a material other than steel.

In the scaffold plank100shown inFIGS. 3 and 4, four (4) reinforcement bars114are depicted as being disposed within respective ones of the four (4) slots extending within the interior of the main body102. Those of ordinary skill in the art will recognize that no reinforcement bars114need be provided within the main body102, and that less than four (4) reinforcement bars114may be included therein. The number of reinforcement bars114, if any, included in the interior of the main body102of the scaffold plank100is dependent upon the level of structural integrity or rigidity desired in relation thereto. Additionally, though the main body102is shown as including four (4) channel members112and three (3) primary reinforcement webs116, those of ordinary skill in the art will recognize that the main body102may be formed to include greater or fewer channel members112and/or primary reinforcement webs116.

As indicated above, no reinforcement bars114need to be provided within the main body102. In this respect, it is contemplated that as an alternative to the reinforcement bars114being included in the main body102, the channel members112may be formed to be of a solid cross-sectional configuration as opposed to partially defining the above-described rectangularly configured slots. In this respect, based upon the particular plastic material used to form the main body102, the formation of the same with the solid channel members102may be sufficient to impart the desired amount of structural integrity/rigidity to the scaffold plank100.

In the second embodiment, the main body102of the scaffold plank100is preferably fabricated via an injection molding process, as is the cover member120thereof. If one or more reinforcement bars114is to be included within the interior of the main body102, such reinforcement bar(s)114will typically be pre-positioned within the mold, with the plastic material thereafter being injection molded about the same, thus resulting in the reinforcement bars114being molded in place. Additionally, as seen inFIG. 3, it is contemplated that the mold may be formed to provide the top surface106of the top wall104with non-skid characteristics through the formation of multiple, generally circular protuberances122thereon, with such protuberances122being arranged in generally parallel rows. As an alternative to being formed to include the protuberances122, the top surface106of the top wall104may be subjected to a follow-up grinding or machining operation subsequent to the molding of the main body102for purposes of applying a texture or roughened feature thereto. The outer surface of the cover member120may also be formed to include a texture or roughened feature. Though the main body102and the cover member120are preferably fabricated via an injection molding process, it is contemplated that either or both of the main body102and cover member120may be fabricated via a vacuum forming or extrusion process. Additionally, though not shown, it is contemplated that the previously described nail holes16and/or frame setting notches18may be formed within the scaffold plank100via processes/techniques similar to those previously described in relation to the scaffold plank10of the first embodiment.

It is contemplated in the scaffold plank100of the second embodiment, the cover member120may be formed as an integral portion of the main body102as opposed to a separate component attached thereto. In this respect, the main body102including the cover member120as an integral portion thereof may be formed or fabricated as a totally symmetrical component or part. Both of the sides or faces of such symmetrical part could be provided with a texture or roughened feature, with the absence of any nail holes16and frame setting notches18allowing the same to be positioned upon scaffolding in any orientation. If formed to include the cover member120as an integral portion thereof, it is contemplated that the main body102will be molded in two identical halves defined by bisecting the side walls108along a common plane. These two symmetrical halves of the main body102(one of which would include the integrally formed cover member120) would be attached to each other via sonic welding or an adhesive to facilitate the formation of the scaffold plank100. Each of the symmetrical halves could be individually fabricated via injection molding, rotational molding, or a vacuum forming process.

Referring now toFIG. 5, there is shown a scaffold plank200constructed in accordance with a third embodiment to the present invention. The scaffold plank200is preferably outfitted with a pair of end connectors202which are cooperatively engaged to respective ones of the opposed ends of the scaffold plank200. The structural and functional attributes of each end connector202(one of which is shown inFIG. 5as exploded from the scaffold plank200) will be described in more detail below.

As seen inFIG. 5, the scaffold plank200is preferably a unitary structure which defines a generally planar, sheet-like top wall204and a generally planar, sheet-like bottom wall206. The top and bottom walls204,206extend in spaced relation to each other along respective ones of a generally parallel pair of planes. Extending perpendicularly between corresponding pairs of the longitudinal edges of the top and bottom walls204,206is a spaced, generally parallel pair of side walls208. Though the inner surfaces of the side walls208are generally planar, the outer surfaces thereof each include an integral upper rail210and an integral lower rail212extending longitudinally therealong in spaced, generally parallel relation to each other. The upper rails210extend along respective ones of the opposed longitudinal sides of the top wall204, and are each substantially flush with the outer surface of the top wall204. Similarly, the lower rails212extend along respective ones of the opposed longitudinal sides of the bottom wall206and are each substantially flush with the outer surface of the bottom wall206. As shown inFIG. 5, each of the upper and lower rails210,212is preferably hollow, though the same may alternatively be formed to have solid cross-sectional configurations. Due to the inclusion of the upper and lower rails210,212thereon, each side wall208defines an elongate slot214, the use of which will also be discussed in more detail below.

The scaffold plank200further comprises a plurality of reinforcement walls216which extend perpendicularly between the inner surfaces of the top and bottom walls204,206. The reinforcement walls216extend longitudinally along the length of the scaffold plank200in spaced, generally parallel relation to each other. Though the reinforcement walls216are equidistantly spaced relative to each other, the spacing between the outermost pair of reinforcement walls216and respective ones of the side walls208is reduced in comparison to the spacing between the reinforcement walls216. As a result, an outer pair of cavities collectively defined by the top and bottom walls204,206, outermost pair of reinforcement walls216, and side walls208each have a width which is less than that of multiple inner cavities which are each collectively defined by the top and bottom walls204,206and an adjacent pair of the reinforcement walls216. As seen inFIG. 5, the scaffold plank200is formed to include five reinforcement walls216. As a result, the scaffold plank200includes four inner cavities and two outer cavities which, as indicated above, are of reduced width as compared to the inner cavities. However, those of ordinary skill in the art will recognize that the number of reinforcement walls216included in the scaffold plank200as shown inFIG. 5is exemplary only, in that greater or fewer reinforcement walls216may be formed to extend between the top and bottom walls204,206. Also exemplary is the spacing between the reinforcement walls216, in that it is contemplated that the reinforcement walls216may be equidistantly spaced relative to each other and to the side walls208, thus causing all of the cavities defined by the scaffold plank200to be of equal size.

It is contemplated that the scaffold plank200of the third embodiment will be fabricated in its entirety from a non-metal material via an extrusion or injection molding process. Exemplary materials for the scaffold plank200include various types of plastics (e.g., glass-filled polyethylene), fiber reinforced composites, or combinations thereof. In this regard, it is further contemplated that the extrusion process preferably used to facilitate the formation of the scaffold plank200may be carried out in a manner wherein various portions of the scaffold plank200are fabricated from a fiber reinforced plastic or composite, with other portions simply being fabricated from a non-reinforced plastic material. More particularly, depending on the level of structural integrity desired for the scaffold plank200, one or more of the reinforcement walls216may be fabricated from a fiber reinforced composite material, with the remainder of the scaffold plank200being fabricated from a plastic material. As indicated above, the extrusion process preferably used to facilitate the formation of the scaffold plank200may be completed such that the scaffold plank200is a unitary structure, despite proscribed areas of the scaffold plank200being fabricated from differing non-metallic materials. As a further variation, the scaffold plank200as shown inFIG. 5may be fabricated entirely from a non-reinforced plastic material, with reinforcing sheets of a fiber reinforced composite material being applied to the outer surface of the top wall204and/or the outer surface of the bottom wall206for purposes of increasing the structural integrity/rigidity of the scaffold plank200. In the scaffold plank200, the outer surface of the top wall204and the outer surface of the bottom wall206are preferably formed to have a roughened or textured feature to provide the scaffold plank200with non-slip characteristics. However, those of ordinary skill in the art will recognize that the non-skid, roughened texture may be included on only the outer surface of the top wall204.

Referring now toFIGS. 5–7, as indicated above, the scaffold plank200of the third embodiment preferably includes a pair of end connectors202cooperatively engaged to respective ones of each of the opposed ends thereof. Each end connector202includes an engagement portion218having a main body220which defines an arcuate, generally concave body surface222. The body surface222spans approximately ninety degrees. Formed within the main body220is a spaced pair of notches224, each of which has a generally V-shaped configuration defining an arcuate lower apex. In addition to the main body220, the engagement portion218of the end connector202includes a spaced, identically configured pair of arms226which are integrally connected to the main body220. Each of the arms226defines an arcuate, generally concave arm surface228which, like the body surface222, also spans approximately ninety degrees. The main body220and arms226are oriented relative to each other such that one of the notches224is disposed between the arms226, with the remaining notch224being disposed between one arm226and one lateral end of the main body220. Importantly, the main body220and arms226are oriented relative to each other such that the arms surfaces228of the arms226are continuous with the body surface222of the main body220. Thus, the arms surfaces228and portions of the body surface222collectively define engagement surfaces which span, in total, approximately 180°. Each arm226also has a generally V-shaped configuration when viewed from a top perspective, with the side walls of the arm26oriented between the notches224being continuous with the side walls of such notches224. One side wall of the remaining arm226is continuous with the side wall of the notch224disposed between the arms226. As seen inFIG. 5, due to the shape of the engagement portion218of the end connector202, the depth of the notch224located between the arms226appears to be greater than that of the remaining notch224due to the side wall of the notch224between the arms226being continuous with one side wall of each of the arms226.

In addition to the engagement portion218, the end connector202includes a plurality of elongate attachment fingers230which protrude perpendicularly from the side of the main body220opposite that including the body surface222formed therein. The fingers230extend in spaced, generally parallel relation to each other, and are each preferably hollow. As is best seen inFIG. 5, the fingers230are sized and configured to be advanceable into respective ones of the cavities defined by the scaffold plank200. In this regard, since the cavities of the scaffold plank200are of differing widths as indicated above, the outermost pair of fingers230of the end connector202are of reduced width as compared to the remaining fingers230. In this regard, the outermost pair of fingers230are sized and configured to be advanceable into respective ones of the outer pair of cavities defined by the scaffold plank200, with the remaining fingers230being sized and configured to be advanceable into respective ones of the inner cavities defined by the scaffold plank200. The advancement of the fingers230into respective ones of the cavities is limited by the abutment of a peripheral portion of the surface of the main body220from which the fingers230extend against corresponding lateral edges of the top and bottom walls204,206and side walls208of the scaffold plank200, in the manner shown inFIG. 6.

Its contemplated that the end connector202will be fabricated from a plastic material via an injection molding process, with the attachment fingers230being integrally connected to the main body220of the engagement portion218. As seen inFIGS. 6 and 7, it is further contemplated that the structural integrity of each end connector202may optionally be increased through the inclusion of a reinforcement plate244therein. The reinforcement244is preferably fabricated from a metal material (e.g., steel), and has a shape which is complimentary to that of the main body220, arms226, and fingers230. More particularly, the reinforcement plate244includes a plurality of reinforcement fingers246which are sized and configured to be advanceable into the interiors of respective ones of the attachment fingers230. Additionally, the reinforcement plate244includes a pair of arcuate reinforcement arms248which are extensible into the interiors of respective ones of the arms226. Since the end connector202is preferably fabricated via an injection molding process, it is contemplated that the reinforcement plate244will initially be included in the mold cavity, with the plastic material used to form the remainder of the end connector202being injected into the mold cavity in a manner effectively encapsulating the reinforcement plate244in the manner shown inFIG. 6.

As indicated above, the cooperative engagement of each end connector202to a respective end of the scaffold plank200is facilitated by the advancement of the fingers230of the end connector202into respective ones of the elongate cavities defined by the scaffold plank200, such advancement terminating when the end of the scaffold plank200is abutted against the main body220of the engagement portion218in the above-described manner. It is contemplated that each end connector202will be maintained in firm engagement to the scaffold plank200through the use of multiple fasteners such as screws250. As seen inFIGS. 5 and 6, one pair of screws250is advanced through respective ones of a pair of openings disposed within one side wall208of the scaffold plank200and into respective ones of a complimentary pair of internally threaded apertures252disposed within one of the outer pair of fingers230of the end connector202. A second pair of screws250is extended through openings in the remaining side wall208and into a complimentary pair of internally threaded apertures252disposed in the remaining finger230of the outer pair. Since the openings in the side walls208of the scaffold plank200are disposed within the bottom surfaces of respective ones of the slots214, the heads of the screws250do not protrude beyond the outermost surfaces of the upper and lower rails210,212of each side wall208, i.e., the heads of the screws250are effectively contained within respective ones of the slots214. It is contemplated that the mechanical interlock between the end connectors202and scaffold plank200facilitated by the screws250may be supplemented by the application of an adhesive to prescribed portions of each end connector202prior to the advancement of the attachment fingers230thereof into the interior of the scaffold plank200. Additionally, the screws250may be omitted in their entirety as a result of the use of an adhesive.

FIGS. 8 and 9depict the manner in which a pair of scaffold planks200which each include the end connectors202attached to each of the opposed ends thereof are interfaced to a horizontal support bar254of a scaffolding support frame256. As seen inFIGS. 6,8and9, the end connector202is engaged to the support bar254such that the arms226extend about the support bar254. More particularly, the outer surface of the support bar254is abutted directly against the arcuate body surface222of the main body220and against the arms surfaces228of the arms226. Advantageously, since the body surface222spans the entire length of the main body220, the scaffold plank200is not susceptible to rocking or tipping when weight or downward force is applied to the longitudinal edges thereof.

Once one end connector202of one scaffold plank200is cooperatively engaged to the support bar254in the above-described manner, one end connector202of the remaining scaffold plank200is itself cooperatively engaged to the same support bar254. In this regard, the arms226of the end connector202of one scaffold plank200are nested into respective ones of the notches224of the corresponding end connector202of the other scaffold plank200in the manner shown inFIG. 9. When the corresponding end connectors202of the scaffold planks200are interfaced to the common support bar254as shown inFIG. 9, the contours of the top surfaces of the arms226results in the distal portions thereof being recessed downwardly relative to the top surfaces of the main bodies220of the engagement portions218of the corresponding end connectors202.

As seen inFIG. 6, further in accordance with the present invention, it is contemplated that each end connector202of each scaffold plank200may optionally be provided with a locking clip258which is preferably fabricated from a resilient metallic material (e.g., steel) and secured to the main body220of the engagement portion218via one or more fasteners such as screws260. It will be recognized that each end connector202may be outfitted with one relatively large locking clip258, or multiple, smaller identically configured locking clips258disposed in spaced relation to each other. The locking clip258is sized and configured to frictionally engage the support bar254in the manner shown inFIG. 6, thus inhibiting the easy uplift of the end connector202out of engagement to the support bar254. Those of ordinary skill in the art will recognize that the inclusion of the locking clip(s)258are optional, and that alternative locking mechanisms may be included in each end connector202to facilitate the secure connection thereof to the scaffolding support frame256.

Referring now toFIG. 10, further in accordance with the present invention, it is contemplated that the slots214included in the side walls208of each scaffold plank200may be used to accommodate edge connectors (not shown) which effectively maintain two or more scaffold planks200in side-by-side attachment to each other, i.e., the longitudinal side wall208of one scaffold plank200is cooperatively engaged to a corresponding side wall200of an adjacent scaffold plank200. InFIG. 10, three scaffold planks200are shown in such side-by-side engagement, with the end connectors202of each set of three interconnected scaffold planks200themselves being cooperatively engaged to a common horizontal support bar254of the scaffolding support frame256. As further shown inFIG. 10, it is also contemplated that a corner connector260may be used in conjunction with two interconnected sets of scaffold planks200, the corner connector260being sized and configured to allow the interconnected sets of scaffold planks200to be effectively joined to each other, despite being disposed at a prescribed angular displacement relative to each other. As shown inFIG. 10, the corner connector260includes an opposed pair of side edges, each of which is formed to include an arcuate, generally concave engagement surface262, a plurality of arms264, and a plurality of notches266. The engagement surface262, arms264and notches266of each side edge are structurally and functionally identical to the body surface222, notches224, and arms226of each end connector202. In this regard, when the end connectors202of the interconnected scaffold planks200of one set are cooperatively engaged to the common support bar254, one side edge of the corner connector260may be cooperatively engaged to the same support bar254, with the arms264of the corner connector260being nested within respective ones of the notches224of the interconnected scaffold planks200, and the arms226of the interconnected scaffold planks200being nested within respective ones of the notches266of the corner connector260.

The corner connector260is preferably fabricated from a plastic material via an injection molding process, with the top surface of the corner connector260also being provided with a roughened, non-slip texture. As seen inFIG. 10, the corner connector260is sized to span approximately 30°, though those of ordinary skill in the art will recognize that the corner connector260may be formed to span differing angular intervals. Additionally, multiple corner connectors260may be cooperatively engaged to the scaffolding support frame256proximate to each other so as to collectively define a span of more than 30°. For example, two corner connectors260as shown inFIG. 10disposed in side-by-side relation to each other would span approximately 60°, with three corner connectors260interlocked to the scaffolding support frame256in side-by-side relation to each other spanning approximately 90°. Though the corner connector260shown inFIG. 10is shown as being sized to be interfaced to two sets of three interconnected scaffold planks200, the corner connector260may alternatively be sized and configured to span between only two interconnected scaffold planks200, or even individual scaffold planks200which are angularly displaced relative to each other.

Additional modifications and improvements of the present invention may also be apparent to those of ordinary skill in the art. In this respect, the planks formed in accordance with the present invention may be used in applications other than for scaffolding. Thus, the particular combination of parts described and illustrated herein is intended to represent only certain embodiments of the present invention, and is not intended to serve as limitations of alternative devices within the spirit and scope of the invention