Configurable scaffolding system

A configurable scaffolding system is configured to facilitate simplified, reconfigurable access to a plurality of horticulture racks. With use of the configurable scaffolding system, operator convenience and safety are improved, and increased plant density in horticultural applications can be achieved.

TECHNICAL FIELD

The present disclosure relates to scaffolding, and in particular to configurable scaffolding systems utilized in connection with horticulture applications.

BACKGROUND

Horticulture racking systems, and other vertical storage, shelving, or racking systems, typically require a ladder, wheeled staircase, or scissor lift to access and/or service elevated racks or shelves. However, such components are often unwieldy, require undesirably wide aisles between racks, or have safety drawbacks. Accordingly, improved scaffolding and similar systems remain desirable.

SUMMARY

A configurable scaffolding system is disclosed, comprising a first work deck, a first vertical upright bracket configured to support the first work deck, and a trim cover, wherein an end of the first work deck is configured to be disposed between a portion of the first vertical upright bracket and a portion of the trim cover in an installed position.

In various embodiments, the first work deck comprises a square tubing frame at least partially covered with a sheet of material.

In various embodiments, the first work deck further comprises a sleeve defining an aperture, whereby the first vertical upright bracket is coupled to the first work deck.

In various embodiments, the configurable scaffolding system further comprises a second vertical upright bracket configured to support the first work deck.

In various embodiments, the first work deck is configured to be disposed between a first horticulture rack and a second horticulture rack, wherein the first vertical upright bracket is configured to be coupled to the first horticulture rack and the second vertical upright bracket is configured to be coupled to the second horticulture rack, and wherein a first end of the trim cover is configured to be coupled to the first horticulture rack and a second end of the trim cover is configured to be coupled to the second horticulture rack.

In various embodiments, the configurable scaffolding system further comprises a decking brace, wherein the decking brace is configured to be coupled between the first vertical upright bracket and the first work deck.

In various embodiments, the decking brace is configured to be coupled between the second vertical upright bracket and the first work deck.

In various embodiments, the configurable scaffolding system further comprises a second work deck, wherein the decking brace is configured to be coupled between the second vertical upright bracket and the second work deck.

In various embodiments, the configurable scaffolding system further comprises a safety flag.

In various embodiments, the first vertical upright bracket comprises a first wall, a second wall, and a third wall extending from the first wall to the second wall, wherein the first wall, the second wall, and the third wall define a channel configured to receive a vertical upright support, and the first wall is disposed opposite the channel from the second wall.

In various embodiments, the first vertical upright bracket further comprises a first tab extending from the first wall, a second tab extending from the second wall, a first attachment rod extending from the first tab, the first attachment rod is configured to be received by the first work deck, and a second attachment rod extending from the second tab, the second attachment rod is configured to be received by a second work deck.

A configurable scaffolding system is disclosed, comprising a first work deck, a second work deck, a first vertical upright bracket configured to support the first work deck and the second work deck, a second vertical upright bracket configured to support the first work deck and the second work deck, and a trim cover disposed between the first work deck and the second work deck. A first end of the first work deck is configured to be disposed between a first portion of the first vertical upright bracket and a first portion of the trim cover in an installed position.

In various embodiments, a second end of the second work deck is configured to be disposed between a second portion of the first vertical upright bracket and a second portion of the trim cover in the installed position.

In various embodiments, the trim cover comprises a first end, a second end, and a tube extending between the first end and the second end.

In various embodiments, the first end of the trim cover comprises a first vertical tab and a second vertical tab whereby the trim cover is configured to be coupled to a vertical upright support of a shelving apparatus, a first horizontal tab extending from the first vertical tab, wherein the first portion of the trim cover comprises the first horizontal tab, and a second horizontal tab extending from the second vertical tab, wherein the second portion of the trim cover comprises the second horizontal tab.

In various embodiments, the first vertical upright bracket comprises a first wall, a second wall, a third wall extending from the first wall to the second wall, wherein the first wall, the second wall, and the third wall define a channel configured to receive the vertical upright support, and the first wall is disposed opposite the channel from the second wall, a first tab extending from the first wall, a second tab extending from the second wall, a first attachment rod extending from the first tab, the first attachment rod is configured to be received by the first work deck, and a second attachment rod extending from the second tab, the second attachment rod is configured to be received by the second work deck.

In various embodiments, the tube is substantially flush with the first work deck and the second work deck.

A method for servicing a horticulture rack is disclosed, the method comprising utilizing a first horticulture rack and a second horticulture rack to grow plants, wherein the first horticulture rack and the second horticulture rack are separated by an aisle, coupling, to the first horticulture rack and to the second horticulture rack, a configurable scaffolding system, wherein the configurable scaffolding system is disposed at least partially in the aisle, and accessing, via the configurable scaffolding system and by a system user, the plants in the first horticulture rack and the second horticulture rack.

In various embodiments, the method further comprises decoupling, from the first horticulture rack and the second horticulture rack, the configurable scaffolding system, and coupling, to the second horticulture rack and to a third horticulture rack, the configurable scaffolding system.

In various embodiments, the configurable scaffolding system comprises a work deck, at least one vertical upright bracket, at least one decking brace, a safety flag, and a trim cover.

The foregoing features, elements, steps, or methods may be combined in various combinations without exclusivity, unless expressly indicated herein otherwise. These features, elements, steps, or methods as well as the operation of the disclosed embodiments will become more apparent in light of the following description and accompanying drawings.

DETAILED DESCRIPTION

The following description is of various exemplary embodiments only, and is not intended to limit the scope, applicability or configuration of the present disclosure in any way. Rather, the following description is intended to provide a convenient illustration for implementing various embodiments including the best mode. As will become apparent, various changes may be made in the function and arrangement of the elements described in these embodiments without departing from the scope of the appended claims.

For the sake of brevity, conventional techniques for racking, storage, and/or shelving systems, modular horticulture, lighting, irrigation, ventilation, drainage systems, and/or the like may not be described in detail herein. Furthermore, the connecting lines shown in various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical customizable scaffolding system and/or related methods of use.

Principles of the present disclosure may be compatible with and/or may be utilized in connection with principles disclosed in U.S. patent application Ser. No. 16/802,036 filed on Feb. 26, 2020, now U.S. Patent Application Publication No. 2020/0268152 entitled “CUSTOMIZABLE SLIDABLE SHELVING AND SUPPORT SYSTEM FOR HORTICULTURE APPLICATIONS.” The disclosure of the foregoing application is incorporated herein by reference in its entirety, including but not limited to those portions that specifically appear hereinafter, but except for any subject matter disclaimers or disavowals, and except to the extent that the incorporated material is inconsistent with the express disclosure herein, in which case the language in this disclosure shall control.

With reference now toFIG.1AandFIG.1B, in various exemplary embodiments, a customizable scaffolding system100(also referred to herein as a configurable scaffolding system) comprises components that interface with and/or attach to or decouple from an existing vertical horticulture racking system (e.g., first horticulture rack50and/or second horticulture rack52). Scaffolding system100allows workers to safely access the various tiers of racking and service plants. Use of scaffolding system100eliminates the need to utilize a ladder, wheeled staircase, or scissor lift. Additionally, use of scaffolding system100allows access rows or aisles between vertical racks (e.g., between first horticulture rack50and second horticulture rack52) to be made narrower, leaving more space for racks and thus significantly improving the density of plants that are able to be grown in a particular space.

Scaffolding system100may be formed from any suitable materials, for example aluminum, steel, high-strength plastics, and/or the like. Components may be machined, stamped, cast, and/or otherwise formed in any suitable manner or process. Additionally, components may be permanently and/or releasable coupled to one another and/or to other systems or devices via any suitable method, for example welding, brazing, and/or mechanical fasteners such as rivets, screws, bolts, and/or the like.

In various exemplary embodiments, scaffolding system100comprises one or more each of a work deck200, a vertical upright bracket300, a decking brace400, a safety flag500(fixed and/or telescoping) and a trim cover600(fixed and/or telescoping). However, additional and/or fewer components may be utilized in certain embodiments, as suitable. In this manner, scaffolding system components (e.g., work deck200, vertical upright bracket300, decking brace400, safety flag500, and/or a trim cover600) of the present disclosure may be coupled between adjacent vertical horticulture racking systems (e.g., first horticulture rack50and second horticulture rack52).

An operator may install/place a scaffolding system100in a particular location in order to access plants in one or more horticulture racks. Thereafter, the scaffolding system100and/or components thereof may be removed from a first location and placed in a second location in order to access plants in other horticulture racks. In this manner, operator access is simplified, safety is increased, and plant growing density and yield may be increased.

With reference toFIG.2throughFIG.4D, a scaffolding work deck200is illustrated, in accordance with various embodiments. Work deck200may be made of a square tubing frame210and covered with a sheet220of material. Sheet220may be “pooch” punched for traction. Stated differently, sheet220may comprise a plurality of raised edges222defining apertures in sheet220. Frame210may include a plurality of longitudinally extending tubes212and a plurality of transversely extending tubes214. Longitudinally extending tubes212and transversely extending tubes214may be connected together with a metal joining process, such as a weld, a solder, and/or a braze.

Work deck200may further include a sleeve216(also referred to as a gusset) at each corner thereof. Each sleeve216may extend through a hole in the tube (e.g., longitudinally extending tube212) at the corner of the work deck200. A centerline axis of each sleeve216may extend substantially orthogonal to the surface of the work deck200. In various embodiments, each sleeve216is substantially flush with sheet220. In various embodiments, each sleeve216is recessed within sheet220. Each sleeve216may be connected to an associated tube (e.g., tube212or tube214) with a metal joining process, such as a weld, a solder, and/or a braze. The work deck200attaches in-between two shelving apparatus (for example, as disclosed in U.S. Patent Application Publication No. 2020/0268152). The work deck200may slide into vertical upright brackets before being secured by a locking trim cover, as described herein. Each corner of the work deck200includes a sleeve216that accepts an attachment rod on the vertical upright bracket300. In this manner, sleeve216provides a reinforced aperture configured to receive an attachment rod for securing the work deck200to an associated vertical upright bracket300.

Sheet220may be made from metal, such as aluminum for example, a high-strength plastic material, a fiber-reinforced composite material, or any other suitable material. The work deck200may be configured to be lightweight enough for a single person to carry and assemble, as scaffolding system100may typically be utilized as temporary and not a permanent scaffolding. The work deck200may be e-coated and/or powder coated. The work deck200may be sized and/or configured as needed, for example depending on the size and configuration of an associated horticulture racking system. In one exemplary embodiment, work deck200is 20 inches wide and 96 inches long, though work deck200may comprise any suitable width and length as desired.

With reference toFIG.5AthroughFIG.6, a vertical upright bracket300is illustrated, in accordance with various embodiments. Vertical upright bracket300may include a body310that is generally U-shaped to define a channel312configured to receive a vertical upright support of a shelving apparatus. In this manner, vertical upright bracket300may be permanently or releasably attached to the vertical upright support at intervals that correspond to the tiers on the racks as determined by the operator. Body310may include a first wall314and a second wall316. First wall314and second wall316may be disposed on opposite sides of channel312. First wall314and second wall316may be oriented parallel to each other. First wall314and second wall316may be connected by a third wall318. Third wall318may be oriented orthogonal to first wall314and second wall316. In this regard, channel312may be defined by first wall314, second wall316, and third wall318. In one exemplary embodiment, the vertical upright bracket300is made of e-coated and/or powder-coated steel.

Vertical upright bracket300may include a first tab320extending from the body310. First tab320may extend from first wall314. First tab320may be oriented orthogonal with respect to first wall314. An attachment rod324(also referred to herein as a first attachment rod) may be mounted to first tab320. Attachment rod324may be configured to be received into a sleeve of a first work deck (e.g., sleeve216of work deck200) to support the first work deck in an installed position with respect to a shelving apparatus.

First wall314and second wall316may include a first set of corresponding apertures330for receiving a first fastener334to extend between the first wall314and the second wall316. First wall314and second wall316may include a second set of corresponding apertures332for receiving a second fastener336to extend between the first wall314and the second wall316. In this manner, body310may be secured to the vertical upright support of the shelving apparatus.

Vertical upright bracket300may further include a second tab322extending from the body310. Second tab322may extend from second wall316. Second tab322may be oriented orthogonal with respect to second wall316. An attachment rod326(also referred to herein as a second attachment rod) may be mounted to second tab322. Attachment rod326may be configured to be received into a sleeve of a second work deck (e.g., sleeve216of work deck200) to support the second work deck in an installed position with respect to a shelving apparatus.

With reference toFIG.6, an assembly view of vertical upright bracket300is illustrated, in accordance with various embodiments. Attachment rod324may be coupled to first tab320via a first fastener340. First tab320may comprise an aperture321for receiving first fastener340. Attachment rod326may be coupled to second tab322via a second fastener342. Second tab322may comprise an aperture323for receiving second fastener342.

With reference toFIG.7A,FIG.7B, andFIG.7C, attachment rod324is illustrated, in accordance with various embodiments. Attachment rod324may comprise a threaded aperture325for receiving fastener340(seeFIG.6). In this regard, attachment rod324may be removably coupled to first tab320(seeFIG.6). However, it is contemplated herein that attachment rod324may be welded to first tab320, in accordance with various embodiments.

With reference toFIG.8, an end vertical upright bracket301is illustrated, in accordance with various embodiments. End vertical upright bracket301is similar to vertical upright bracket300, except that end vertical upright bracket301only includes one tab and associated attachment rod. In this manner, end vertical upright bracket301may be configured to be coupled to the last (i.e., the end) vertical upright support of a row of shelving apparatus. In this manner, end vertical upright bracket301may support a work deck at only one side of the bracket.

With reference toFIG.9, a decking brace400is illustrated, in accordance with various embodiments. Decking brace400includes a square tube420. In various embodiments, the square tube420is e-coated and/or powder coated. Square tube420may be made of a metal material, such as steel for example. In one exemplary embodiment, the decking brace400is made of e-coated and/or powder-coated square steel tubing with a plurality of attachment rods on the top face491(for example, the same or similar rods as on the vertical upright brackets300(seeFIG.6)). In various embodiments, decking brace400includes four attachment rods (e.g., attachment rod402, attachment rod404, attachment rod406, and attachment rod408. The attachment rods402,404,406,408may be made of a metal material, such as stainless steel for example.

With reference toFIG.10AandFIG.10B, an assembly view and an assembled view, respectively, of the decking brace400are illustrated with the attachment rods omitted for clarity purposes. Decking brace400may further include a plurality of sleeves (e.g., sleeve410, sleeve411, sleeve412, sleeve413, sleeve414, and/or sleeve415) (also referred to as gussets)). The sleeves410,411,412,413,414,415may be sized to accept the attachment rods (e.g., attachment rod324and/or attachment rod326) of vertical upright bracket300(seeFIG.5A) from the bottom face492of square tube420. In various embodiments, a first plurality of sleeves (i.e., sleeve410, sleeve411, and sleeve412) are disposed at a first end of decking brace400and a second plurality of sleeves (i.e., sleeve413, sleeve414, and sleeve415) are disposed at a second, opposite end of decking brace400. Including multiple sleeves on the ends of the decking brace400allows the operator to vary the actual width of the decking by predetermined increments (e.g., two inch increments or any other desired increment dimensions). For example, with reference toFIG.11, decking brace400is installed onto vertical upright support10and vertical upright support11with the ends of decking brace400extending past vertical upright support10and vertical upright support11. In this regard, the distance between vertical upright support10and vertical upright support11may be decreased by inserting the attachment rod of first vertical upright bracket300ainto sleeve412(seeFIG.10B) of decking brace400and inserting the attachment rod of second vertical upright bracket300binto sleeve413(seeFIG.10B). In contrast, the distance between vertical upright support10and vertical upright support11may be increased by inserting the attachment rod of first vertical upright bracket300ainto sleeve410(seeFIG.10B) of decking brace400and inserting the attachment rod of second vertical upright bracket300binto sleeve415(seeFIG.10B).

With reference toFIG.10AandFIG.10B, a plurality of fasteners (i.e., fastener430, fastener431, fastener432, and fastener433) may be coupled to square tube420. The attachment rods402,404,406,408may be coupled to square tube420via the plurality of fasteners430,431,432,433—e.g., similar to attachment rod324ofFIG.6throughFIG.7C.

With reference toFIG.12, decking brace400gives operators the ability to make a wider scaffolding deck as desired by connecting two work decks (i.e., work deck200aand work deck200b) side-by-side by setting the attachment rods (e.g., see attachment rod324and attachment rod326ofFIG.5A) of first vertical upright bracket300aand second vertical upright bracket300binto the sleeves (e.g., see sleeve410and sleeve415ofFIG.10B) of decking brace400, then laying work deck200aand work deck200bon top of the decking brace400with the attachment rods (e.g., see attachment rods402,404,406,408ofFIG.9) on the decking brace400fitting into the corresponding sleeves (e.g., see sleeves216ofFIG.4A) in work deck200aand work deck200b.

With reference toFIG.13, a safety flag500is illustrated, in accordance with various embodiments. In an exemplary embodiment, the safety flag500is made of e-coated and/or powder coated steel tubing. Safety flag500may include a tube502extending between a first end504of the safety flag500and a second end506of the safety flag500. First end504of safety flag500may comprise a first tab508and a second tab509. First tab508and second tab509may be configured to receive a first pin514(e.g., a cotter-style pin) to lock the first end504of the safety flag500to a vertical upright support (e.g., vertical upright support12ofFIG.15). Second end506of safety flag500may comprise a first tab510and a second tab511. First tab510and second tab511may be configured to receive a second pin515(e.g., a cotter-style pin) to lock the second end506of the safety flag500to a vertical upright support (e.g., vertical upright support13ofFIG.15).

Safety flag500may further include a visual member520extending from tube502. Visual member520may provide a physical and visual barrier which may tend to prevent workers from falling off the ends of the work decks.

The safety flag500may be configured as one of at least 2 versions, for example: a telescoping version (see safety flag501ofFIG.14) that allows operators to fit the flag to a double-wide work deck assembly, and a fixed version (see safety flag500ofFIG.13) for use when a single-wide work deck assembly is desired.

With reference toFIG.15, safety flag500is illustrated installed to vertical upright support12of a first shelf apparatus and vertical upright support13of a second shelf apparatus.

With reference toFIG.16, safety flag501is illustrated installed to vertical upright support14of a first shelf apparatus and vertical upright support15of a second shelf apparatus.

With reference toFIG.17A,FIG.17B, andFIG.17C, a trim cover600is illustrated, in accordance with various embodiments. In one exemplary embodiment, the trim cover600is made from e-coated and/or powder-coated steel. Trim cover600may include a tube602extending between a first end604of the trim cover600and a second end606of the trim cover600. First end604of trim cover600may comprise a first tab608(also referred to herein as a first vertical tab) and a second tab609(also referred to herein as a second vertical tab). First tab608and second tab609may be configured to receive a first pin614(e.g., a cotter-style pin) to lock the first end604of the trim cover600to a vertical upright support (e.g., vertical upright support16ofFIG.19). Second end606of trim cover600may comprise a first tab610(also referred to herein as a first vertical tab) and a second tab611(also referred to herein as a second vertical tab). First tab610and second tab611may be configured to receive a second pin615(e.g., a cotter-style pin) to lock the second end606of the trim cover600to a vertical upright support (e.g., vertical upright support17ofFIG.19).

First end604of trim cover600may comprise a first horizontal tab621extending from first tab608and a second horizontal tab622extending from second tab609. Second end606of trim cover600may comprise a first horizontal tab623extending from first tab610and a second horizontal tab624extending from second tab611. First horizontal tab621and first horizontal tab623may be configured to secure a first work deck (e.g., work deck200aofFIG.19) in an installed position. Second horizontal tab622and second horizontal tab624may be configured to secure a second work deck (e.g., work deck200bofFIG.19) in an installed position.

The trim cover may be configured as one of at least 2 versions, for example: a fixed version (see trim cover600ofFIG.17A) for use when a single-wide work deck assembly is utilized (seeFIG.19), and a telescoping version (see trim cover601ofFIG.18) that allows operators to fit the cover to a double-wide work deck assembly (seeFIG.20).

With reference toFIG.19, trim cover600may be utilized for multiple purposes, for example (i) to fill a gap between work decks (i.e., work deck200aand work deck200b) that will prevent tripping, and (ii) to lock the work decks200a,200bsecurely into the receiving deck brace or vertical upright bracket rods (see first vertical upright bracket300a). An end of work deck200bis captured between second horizontal tab622and first vertical upright bracket300a. Tube602may be disposed between first work deck200aand second work deck200b. Tube602may be substantially flush with first work deck200aand second work deck200b.

With reference toFIG.20, telescoping trim cover601is installed over a double-wide work deck arrangement including work deck200aand work deck200bin a side-by-side configuration. First vertical upright bracket300ais coupled to vertical upright support16and second vertical upright bracket300bis coupled to vertical upright support17. Decking brace400is installed over first vertical upright bracket300aand second vertical upright bracket300b. Decking brace400supports a first end of work deck200aand a first end of work deck200b. Telescoping trim cover601is coupled between vertical upright support16and vertical upright support17.

Via use of the exemplary systems and methods disclosed herein, plant growing density may be increased and operator safety improved. It will be appreciated, however, that exemplary systems disclosed herein are not necessarily limited to horticulture applications and can be applied or utilized in connection with service and/or access to various shelving or storage systems used in a variety of industries or applications, again facilitating improved operator safety as well as potentially increased storage density and/or space utilization.

In the foregoing specification, various embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present disclosure as set forth in the claims below. Accordingly, the specification is to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present disclosure. Likewise, benefits, other advantages, and solutions to problems have been described above with regard to various embodiments. However, benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the claims. As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Also, as used herein, the terms “coupled,” “coupling,” or any other variation thereof, are intended to cover a physical connection, an electrical connection, a magnetic connection, an optical connection, a communicative connection, a functional connection, and/or any other connection. When language similar to “at least one of A, B, or C” is used in the claims, the phrase is intended to mean any of the following: (1) at least one of A; (2) at least one of B; (3) at least one of C; (4) at least one of A and at least one of B; (5) at least one of B and at least one of C; (6) at least one of A and at least one of C; or (7) at least one of A, at least one of B, and at least one of C.