Modular ladder frame playground system

The present invention relates to playground equipment and, more particularly, to a playground apparatus incorporating modular construction, which permits rapid simplified assembly, modification and universal arrangement of playground equipment modules without tools.

FIELD

The present invention relates to playground equipment and, more particularly, to a playground apparatus incorporating modular construction, which permits rapid simplified assembly, modification and universal arrangement of playground equipment modules without tools.

BACKGROUND

In the past, playground equipment typically consisted of a single-unit device such as a slide, a swing, a set of swinging bars or the like. These components were sometimes permanently combined during manufacture. Modern playground equipment, however, has become a conglomeration of many playground components or modules attached to one another by various means and in a variety of arrangements. These changes in playground equipment have evolved to meet the demands of a new generation of child-care facilities. In the past, most playground equipment was found in large schoolyards where space was plentiful and basic equipment was sufficient. However, with the ever-increasing number of day-care facilities, play centers for learning and training of children and many other child-care facilities, the requirements for playground equipment to meet a great variety of needs have created a dilemma for the producers of the equipment.

For example, if a user is providing equipment for use in play and learning classes for children of various ages and abilities, such as the Gymboree® Play & Music® program, that involve age-appropriate activities, this would involve a mix of equipment, play and activities on mats. One of the more demanding aspects of the Gymboree® programs is the requirement to adapt the activity area for the next age group in the 5-10 minutes that are available between sessions. As in many child-care and learning facilities, the space requirements vary. While one facility with a large playground to accommodate large numbers of children may require equipment having several varied components, another smaller operation may have limited space, which requires the equipment to be limited to only one or a small number of components that must be specifically arranged to fit the available space.

While any playground equipment having a variety of components may obviously be assembled and disassembled, the equipment available prior to this disclosure relies on concrete footings and connecting devices that are rendered permanent by a variety of means and does not lend itself to be quickly and easily assembled and custom configured to meet the varied needs of the present generation of equipment users. Specifically fixed playground equipment does not allow for continuous adaptations to the play environment to accommodate children of various ages and abilities or to alter the play setting to provide additional challenge in consideration of the learning that children experience during use of the equipment. Thus, there is a need for a safe and sturdy modular playground system with a small number of module assembly mechanisms to which all playground modules may be attached that permits simplified transportation, assembly and modification of unattached playground modules of varied types without tools.

This unique design for a Ladder with Fixed and Removable Rungs is part of a system of components that may be fitted together to form a variety of arrangements, and when further combined with other special platforms, barriers, and climbing-activity components to name a few, are intended to inspire fitness activity and physical development in young children and those arrangements of components further perform that in ways that also serve to enhance cognitive and social developmental realms in the children who use the overall play equipment. This Ladder with Removable Rungs may also be used in other combinations to form additional structures and structural systems for other purposes than play. This Ladder with Removable Rungs has as a basic characteristic, a method included in its design that allows some of the horizontal rung components to be removed and repositioned by persons when in the process of reconfiguring the physical arrangement of the overall structure, of which this ladder is a key component. This process may be accomplished without the use of tools, only requiring the hands to fit and secure the components in place, or, conversely, to disassemble the components for reconfiguration or storage.

SUMMARY

The disclosure describes a unique modular construction apparatus that greatly enhances the building, efficient transportation, assembly and utility of modern playground equipment. More specifically, the disclosure provides a unique nucleus around which a modular construction of playground equipment may be quickly and easily assembled. This nucleus is defined as a modular ladder frame assembly. This mechanism comprises three or more modular ladder frames, a lockable deck and a plurality of connectors. The modular ladder frame assembly is connected to one or more brace mechanisms. The system is constructed of three or more modular ladder frames connected at the ends by a plurality of connectors thereof so as to form a configuration for attachment thereto of a lockable deck, and subsequently, the brace mechanisms. As will be seen in more detail as the description continues, the modular ladder frame playground system is specifically designed for quick and easy assembly of a variety of brace mechanisms that comprise playground equipment modules, such as stairways, ladders, slides, fish-eye windows, safety rails, game devices, tunnels, walkways and the like. Other systems, methods, features and advantages of the example embodiments will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description.

DETAILED DESCRIPTION

The purpose of this system disclosed is to create a modular ladder frame playground system that is stable and can be reconfigured extremely rapidly without tools. The core of the modular ladder frame playground system is a modular ladder frame assembly mechanism100.FIG. 1is a perspective view of a modular ladder frame assembly mechanism100.FIG. 1illustrates one embodiment of the modular frame assembly100that comprises three or more modular ladder frames101A,101B and101C, a plurality of connectors130and132, floor puzzle133and a lockable deck126. Three or more modular ladder frames101A,101B and101C are connected at the top and bottom by a plurality of connectors130and132. A lockable deck126is inserted between these modular ladder frames, which, by virtue of having rubber cleats or other spring-like elements on its edges, forces the top and bottom connections to lock into place (not shown inFIG. 1). The lockable deck126also aligns the modular ladder frames101A,101B and101C into a regular configuration as shown inFIG. 1, which, in this embodiment, is a triangular configuration. The regular configuration of the modular ladder frame assembly may be any geometric shape, including, but not limited to, triangular, rectangular, square, octagonal and the like. The addition of nonskid flooring beneath the modular frame ladder playground system provides additional stabilization.

FIG. 2is a perspective view of a modular ladder frame201with removable rungs206and nonremovable rungs202and204. The modular ladder frames201themselves can be configured in many ways, the primary requirement being providing rungs202,204and206on which a lockable deck(s) (not shown) can be placed to provide the locking force necessary to stabilize the system. In the example shown inFIG. 2, nonremovable or permanent rungs202and204are combined with removable rungs206to better accommodate users moving over and through the system when complex configurations are created. The modular ladder frames201comprise vertical supports238that run through the length of the modular ladder frames201. Structurally, it is only necessary that the rungs be of sufficient number and rigidity to impart sufficient integrity to the modular frame assembly for the anticipated loads.

FIG. 3is a cross-sectional view of the removable rungs306of the modular ladder frame301. The cross section of the removable rungs306of the modular ladder frame301comprises tubular pipe casing308, index button322, a compression spring310, Sleevie Wonder312, Latch Bar314, Pins329, which secure the Sleevie Wonder in the tubular pipe casing308and which retain the compression spring310. The components of removable rung306interact to allow for the secure placement and removal of the removable rung306from the modular ladder frame301to accommodate the use of the playground system for various sizes and ages of children.

FIG. 4is a perspective view of the floor puzzle433that is associated with the horizontal support of the modular ladder playground system. The floor puzzle433is placed on the floor either as one unit or multiple connecting units. The floor puzzle433inFIG. 4illustrates a three unit configuration. The floor puzzle433functions to receive the base connectors as shown inFIG. 7, two aperture base connectors430A, three aperture base connectors430B, and four aperture base connectors430C. The floor puzzle433along with the base connectors serve to support the modular ladder playground system as shown inFIG. 1,FIG. 9B,FIG. 9CandFIG. 11.

FIG. 5is a perspective view of the lockable deck526of the modular ladder frame assembly. A lockable deck526is inserted between these modular ladder frames, which, by virtue of having rubber cleats or other spring-like elements on its edges, forces the top and bottom connections to lock into place (not shown inFIG. 5). The lockable deck526also aligns the modular ladder frames501A,501B and501C into a regular configuration as shown inFIG. 1.

FIG. 6Aa detailed view of the underside of the lockable deck626of the modular ladder frame assembly (not shown). The detailed view of the lockable deck626illustrates the hook640and the top connectors630of the modular frame assembly600, that are shown and discussed in more detail inFIG. 8AtoFIG. 8Ebelow. The sides of the lockable deck626connect to the modular frame by lockable deck latch647, hook640and cleats645that securely and snugly fit onto and/or against the rungs of the modular ladder frame assembly. A lockable deck626is inserted between these modular ladder frames, which, by virtue of having a latch647or other spring-like elements on its edges, forces the top and bottom connections to lock into place as shown inFIG. 6. One skilled in the art understands that the latch647can be any type of element or mechanism that forces the secure connection of the lockable deck626into place on the modular frame assembly. The hooks640allow for a better fit to the modular frame.

FIG. 6Bis a 3-D perspective view of the bottom of the lockable deck626of the modular ladder frame assembly (not shown).FIG. 6Cis a 3-D perspective view of the bottom of the lockable deck626that is attached to the modular ladder frame assembly600. The embodiments of the lockable deck inFIG. 6BandFIG. 6Chave a triangular shape. The sides of the lockable deck626connect to the modular frame by lockable deck latch647that snugly fit onto or against the modular ladder frame assembly600at the sides of the lockable deck626. A lockable deck626is inserted between these modular ladder frames, which, by virtue of having lockable deck latches647or other spring-like elements on its edges, force the cleats645and hooks640to lock into place as shown inFIG. 6C. One skilled in the art understands that the lockable deck latches647can be any type of element or mechanism that forces the secure connection of the lockable deck626into place on the modular frame assembly.

FIG. 6Dis a 3-D perspective view of the bottom of the lockable deck626of the modular ladder frame assembly (not shown).FIG. 6Eis a 3-D perspective view of the bottom of the lockable deck626that is attached to the modular ladder frame assembly600. The embodiments of the lockable deck inFIG. 6DandFIG. 6Ehave a cross or square shape. The sides of the lockable deck626connect to the modular frame by lockable deck latches647that snugly fit onto or against the modular ladder frame assembly600at the sides of the lockable deck626. A lockable deck626is inserted between these modular ladder frames, which, by virtue of having hooks640and lockable deck latches647or other spring-like elements on its edges, force the hooks640, cleats645and lockable deck latches647to lock into place as shown inFIG. 6C. One skilled in the art understands that the lockable deck latches647can be any type of element or mechanism that forces the secure connection of the lockable deck626into place on the modular frame assembly.

FIGS. 7A to 7Eare cross-sectional views of the base connectors of the modular ladder frame assembly. The base connectors connect to stabilize the base of the modular ladder frame.FIGS. 7A,7B and7C illustrate cross-sectional top views of three embodiments of base connectors730. The embodiment illustrated inFIG. 7Ais a two aperture configuration730A. The embodiment illustrated inFIG. 7Bis a three aperture configuration730B. The embodiment illustrated inFIG. 7Cis a four aperture configuration730C.FIG. 7Dillustrates one embodiment of the base connector that comprises a bottom plate731and a tubular protuberance734with a round top736that fits into a hollow portion738of a modular ladder frame.FIG. 7Eillustrates one embodiment of the base connector that comprises a bottom plate731and two tubular protuberances734with a round top736that fits into two hollow portions738of a modular ladder frame.FIG. 7Eillustrates the rounded tops736on the tubular protuberances734that facilitate the assembly of the frames into composite towers by aligning the legs of the frames to the base connectors. In order to precisely establish the spacing of the tubular protuberances734, and thereby the ladder frames, the tubular protuberances734are inset into recesses in the base connector. This arrangement of a stepped connection also adds strength and rigidity between the tubular protuberances734and the base connector.

FIGS. 8A to 8Eare various views of the top connectors of the modular ladder frame assembly. The top connectors connect to stabilize the top of the modular ladder frame.FIGS. 8A,8B and8C illustrate top views of three embodiments of top connectors832. The embodiment illustrated inFIG. 8Ais a two aperture configuration832A. The embodiment illustrated inFIG. 8Bis a three aperture configuration832B. The embodiment illustrated inFIG. 8Cis a four aperture configuration832C.FIGS. 8D and 8Eillustrate two side views of one embodiment of a two aperture top connector832A.FIG. 8Dillustrates one embodiment of a three aperture top connector832B that comprises a top plate839, ladder connecting tubular protuberances834and rounded end836that fits into a hollow portion838of a modular ladder Frame.FIG. 8Eillustrates one embodiment of a two aperture top connector832A that comprises a top plate839, two ladder connecting tubular protuberances834with round end836. In the embodiment shown inFIG. 8E, the internal connector842can be connected by any means known to one of ordinary skill in the art, such as by screwing or tapping.

FIG. 9Ais a side view of one embodiment of the modular frame assembly playground system980of the present disclosure that comprises a modular ladder assembly900and two embodiments of brace mechanisms950and960. While single towers made of three or more modular ladder frames, such as those illustrated inFIG. 1, are inherently stable for compression loads, additional stability is required for lateral loads. This is achieved by placing side brace mechanisms950and960. In this example, shown inFIG. 9A, these brace mechanisms950and960are comprised of play equipment modules, such as climbers950and slides960. The weight of play equipment modules is sufficient to stabilize the towers for most uses; however, additional stability is added when the modular ladder frame playground system980is installed on a nonskid surface,970which tends to prevent the braces from sliding away from the towers.

FIG. 9Bis a 3-D side view of one embodiment of the modular frame assembly playground system980of the present disclosure that comprises a modular ladder frame assembly900and two embodiments of the brace mechanisms950and960. In this example, shown inFIG. 9B, the modular ladder frame900comprises a brace mechanism960or slide and a climber950and two lockable decks926installed on a nonskid surface970, which tends to prevent the braces from sliding away from the towers.

FIG. 9Cis a 3-D side view of one embodiment of the modular frame assembly playground system980of the present disclosure that comprises a modular ladder frame assembly900and one embodiment of the brace mechanism960, a slide. In this example, shown inFIG. 9C, the modular ladder frame assembly900comprises brace mechanisms960or slide and950, climber lockable decks926installed on a nonskid surface970, which tends to prevent the braces from sliding away from the towers. The lockable decks926shown are both a triangular and a square or cross shape; however, one skilled in the art understands that many geometric shapes are possible. The two lockable decks926are shown twice in the figure, once as attached to the modular frame assembly900and once as separated from the modular frame assembly with the underside exposed. The lockable decks926with the underside sides exposed show cleats945and hooks940and lockable deck latches947. As described above, inFIGS. 6A to 6E, lockable decks926are inserted between these modular ladder frames900, which, by virtue of having cleats945and hooks940and lockable deck latches947or other spring-like elements on its edges, force the cleats945and lockable deck latch947to lock into place.

FIGS. 10A,10B and10C illustrate one embodiment of a brace mechanisms1050—a rocking climber. Other brace mechanisms may comprise various playground equipment modules, including, but not limited to, stairways, ladders, slides, fish-eye windows, safety rails, game devices, tunnels, walkways and the like.FIGS. 10A and 10Billustrate side views of one embodiment of the brace mechanisms1050of the modular frame playground system980. The embodiment inFIGS. 10Aillustrates the hooks1051, the top arch rail1052, the bottom arch rail1054and the side arch rail1058of the rocking climber embodiment. The embodiment inFIG. 10Billustrates a view of the side arch railing1058.FIG. 10Cillustrates the center portion1056attached to the railings.

FIG. 10Cillustrates a perspective view of the center portion1056of one embodiment of a brace mechanism1050. The center portion1056may comprise various embodiments of climbing structures. In this example, the center portion1056is a fitted net, but any number of other climbing opportunities, such as rungs could be used.

The rocking climber brace mechanism shown inFIG. 10A-C,1050illustrates the synergy between various brace mechanisms and the ladder frame. The central idea of the rocking climber1050is, in addition to bracing the ladder frame, to provides a means of access to the decks at all of their various elevations. SeeFIGS. 9A-9C. Since rocking climber brace mechanism1050must accommodate a wide variety of ages, hooks1051are provided at either end which not only secure the rocking climber brace mechanism1050in place but also provide stability to the system by triangulating between the removable rung on which it rests and the nonskid floor. Because of the ability of the system to be rapidly reconfigured for a wide variety of play experiences the rocking climber brace mechanism1050may also be used at ground level. Repeating the top arch rail1052on the opposite side, the bottom side rail1054now allows the device to function as a rocker on the floor. In addition to rocking the device can also be spun around.

Since younger children need stability support while climbing, a top arch rail1052is provided comprising an arch shape so that it readily falls to the hand in all possible orientations. The top arch rail1052and bottom arch rail1054require structural rigidity and an another outside arch rail arch1058is placed on the outside of the rocking climber1050on both sides. These small outside arches1058also serve to prevent the railing arches from collapsing should pressure, such as sitting, be applied to them since, should such pressure be encountered, the device rolls out of harm's way.

FIG. 11is a perspective view of an assembled modular ladder frame playground system showing playground equipment modules attached to the modular ladder frame assembly mechanism1100and three brace mechanisms1190, illustrated inFIGS. 1-10. The three brace mechanisms1190are two embodiments of a climbing structure and a slide connected to the modular ladder frame assembly mechanism1100. In the system of the present disclosure, each additional component adds cumulatively to its stability of the overall system. The three or more modular ladder frames with top and bottom connectors make a frame that will stand on its own. By inserting the lockable deck with the top connectors, the stability of the system increases. Placing the brace mechanisms on the modular ladder frame assembly adds heft to the system and braces the towers. Thus, a completed modular ladder frame playground system is a very stable structure composed of separate components that are mutually dependent.

The Ladder with Removable Rungs consists of two basic sub-assemblies, the Ladder Frame Assembly (SeeFIG. 12) and the Removable Rung Assembly (SeeFIG. 13). In an exemplary embodiment, the Ladder Frame Assembly1201consists of a frame (SeeFIG. 12) composed of two Tubular Ladder Pipe Segments1205and one Upper Fixed Rung1202, and one Lower Fixed Rung1204, that are permanently affixed to one another, and also includes 8 Receiver Cups1207that are captured in holes drilled in the Tubular Ladder Pipe Segments1205by means of a built-in catch in the Receiver Cups1207, four Receiver Cups1207per Tubular Ladder Pipe Segment1205, and positioned so that they are directly adjacent to one another, and facing one another. Each Receiver Cup1207also has a rectangular slot passing partway through its center axis, transverse to the long axis of the Tubular Ladder Pipe Segments1205, having its long axis parallel to the long axis of the Tubular Ladder Pipe Segments1205, for the purpose of admitting the Latch Bar1214. This slot intersects with a rectangular slot of the receiving cup1207that runs perpendicular to the rectangular slot, thereby securing the Removable Rung Assembly to the Ladder Frame Assembly.

A related assembly, the Removable Rung Assembly (SeeFIG. 13), is fitted to Ladder Frame1305, which is fitted with Receiving Cups1307at each rung location [along] its length, in an exemplary embodiment, is constructed of a Tubular Rung Segment1308having three small Holes near one end, and one Hole near the other end, which are all aligned along a tangent line that is positioned on the outer Tubular Rung Segment1308diameter, and is parallel to the longitudinal axis of the Tubular Rung Segment1308. The Holes at the first end allow a special adapter, the Sleevie Wonder1312. The Sleevie Wonder1312comprises a flange to stop it in the pipe during assembly and a Rectangular Hole at the flanged end to admit the Latch Bar1314to be slipped inside the slotted end of the Tubular Rung Segment1308.

A Latch Bar1314is then slipped into the Rectangular Hole in the end of the Sleevie Wonder1312. The Latch Bar1314has two notches in its upper side to secure the bar in either its open or closed positions. A Release Button1322that has one side relieved to match the radius of the Tubular Rung Segment1308, and a hollow area molded into its body is secured to the Latch Bar1314by expanding this opening so that it may pass the Latch Bar1314and spring back to be held securely by the body of the Sleevie wonder1312. The Sleevie Wonder1312is secured with a pin1329through a slot in the Latch Bar1314that is nearest the arrow point end, securing the Latch Bar1314to the rest of the assembly such that it may be released to slide along the slot by means of the Release Button1322and spring1310, and by that means be either fully extended or fully retracted by hand. Once released by the Release Button1322the Latch Bar1314is locked in position by the Catch Lever1313that is integral with the Sleevie Wonder1312. The other end of the Removable Rung Assembly is completed having the second Sleevie Wonder1312, positioned so that it is parallel to the first Sleevie Wonder1312. The second Latch Bar and the second Sleevie Wonder1312are secured to the Tubular Rung Segment1308using a pin that passes through the Tubular Rung Segment1308, through the Sleevie Wonder1312, and through the hole in the Latch Bar1314thereby forming the “Fixed” Latch Bar1314end of the Removable Rung Segment Assembly.

To assemble a Removable Rung Segment1406Assembly to a Ladder Frame Assembly (SeeFIG. 14), a Removable Rung Segment Assembly having its retractable Latch Bar1414is prepared by manually depressing the Latch Bar1414into the fully retracted position while simultaneously depressing the Release Button1422which is then held by a Catch Bar1413that intersects with a notch in the Latch Bar1414(seeFIGS. 14Aand B). The fixed Latch bar1414(seeFIG. 14C) is then inserted fully into any of the Receiver Cups1407, allowing the other end—having the retractable Latch Bar1414still fully retracted—to be rested in the slot portion of any opposite Receiver Cup1407. Next the retracted Latch Bar1414is allowed to extend fully into the Receiver Cup1407by the force of the Spring1410by again depressing the Release Button1422, aligning its arrow-shaped end to align with the rectangular slot inside of the Receiver Cup1407. Now the Removable Rung Segment Assembly is be “locked” into position by the Catch Lever1413(seeFIG. 14D) on the body of the Sleevie Wonder.

A Removable Rung Segment Assembly may be removed from a Ladder Frame Assembly (seeFIGS. 14Eand F) by pressing the Release Button1422and the arrow shaped point of the Latch Bar1414is depressed by the action of lifting the Removable Rung and the Latch Bar1414is held in its retracted position by the second notch on the Latch Bar1414.