# Patent

## Title
Dual action latching horizontal scaffold member

## Abstract

One embodiment of the invention is a horizontal scaffold member having a primary end connector and a secondary end connector. Each end connector is configured to couple to a cup on a vertical scaffold member. Each end connector includes a wedge assembly having a handle and a wedge, movable with respect to the wedge head to a latched and unlatched position. The primary wedge assembly is connected to the secondary wedge assembly by a cable, and configured so that moving the primary wedge assembly to a unlatched position also moves the secondary wedge assembly to an unlatched position.

## Background
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit of U.S. Provisional Application No. 61/462,938, filed on Jan. 25, 2011, and that application is hereby incorporated by reference.


FIELD OF THE INVENTION
This invention relates to modular scaffolding systems that are erected as impermanent structures to support platforms, and in particular to improve horizontal scaffold members used in these modular scaffold systems. Scaffolding is used, inter alia, in the industrial, commercial, petro-chemical, power source, general industry and residential construction markets.
BACKGROUND
In 2008, the Bureau of Labor Statistics' Census of Fatal Occupational Injuries (CFOI) reported 88 fatalities occurred in the year 2007 related to the use of scaffolds and many more injuries. Twenty-seven percent (27%) of the fatalities and many of the injuries involved falls off of welded frame scaffolds over 25 feet high during the installation of the scaffolds. Safety officials recommend that scaffolding falls be pre-empted through the use of sequential erection techniques. This involves installing guardrails and standards at regular distances along the scaffold such that the exposed platform edge is not greater than a bay length between intervals. The use of safety harnesses or belts tethered to guardrails during the erection process is also a recommended safety practice. However, the use of safety harnesses to deter fall injuries during scaffold erection is quite limited due to the components used in conventional scaffolds. The nature and design of conventional scaffold components, as described herein, disadvantageously do not allow the effective use of safety harnesses during the erection process.
Tube and coupler scaffolds are so-named because they are built from tubing connected by coupling devices. Due to their strength, they are frequently used where heavy loads need to be carried, or where multiple platforms must reach several stories high. Components of scaffolds include vertical standards having coupling rings or rosettes, horizontal components such as ledgers and guardrails coupled to the coupling rings or rosettes, footings, decks/platforms and diagonal braces. Their versatility, which enables them to be assembled in multiple directions in a variety of settings, also makes them difficult to build correctly.
Conventional scaffolding systems have various components. FIG. 1 illustrates a supported scaffold 100 consisting of one or more platforms supported by rigid support members such as poles, tubes, beams, brackets, posts, frames and the like. More specifically, the supported scaffold 100 includes the following components: deck/platform 101, horizontal members, or ledgers 102, and vertical standards 103. Additional components include diagonal braces to increase the stiffness and rigidity of the scaffold 100.
FIG. 2 is an illustration of a vertical standard 103. Vertical standards are typically cylindrical tubes 200 comprised of hot-dip galvanized steel or aluminum. A collar with an expanded or reduced diameter or a spigot at either or both ends of the vertical standard facilitates the joining of vertical standards from end to end. Rosettes 201 are positioned and then welded or otherwise attached along the tubes providing connections for horizontal members and diagonal braces. The vertical standard can have from one to 8 or more rosettes placed along the tubing using a predetermined spacing between rosettes, for example, about every 20 inches.
FIG. 3 illustrates a ledger 102. A ledger is a horizontal member that serves as both a guardrail and bracing element. The ledger 102 is comprised of tubing 300, heads 301 and wedges 302. Ledgers 102 are available in different lengths, depending on the scaffolding bay length, deck type and load. It is the conventional manner in which these ledgers are coupled to vertical standards that contribute to scaffolding falls as further described herein. Once the tubing on a level is installed, decks or platforms 101 made of, e.g., hot-dip galvanized steel, aluminum, wood or an aluminum frame with plywood board are installed to allow workers to traverse the scaffold 100 and install the guardrails (e.g., ledgers 102).
Referring now to FIG. 4, wedge 302 is shown being hammered into the slot or gap of head 301 at the end of a ledger 102 so as to couple it to the rosette 201 of the vertical standard 200. This must be done by a worker first at the proximate end of the ledger 102 and then at the distal end of the ledger 102. However, as the proximate end of the ledger 102 is being coupled to the vertical standard using the wedge 302, the distal end of the ledger 102 is free and uncoupled, that is, until the worker can traverse the platform to the distal end of the ledger 102 and hammer in a wedge 302 at the distal end. During this time, the distal end of the ledger 102 remains uncoupled from the vertical standard. Hence, if the installer is harnessed to the ledger 102 and the scaffold tilts toward the uncoupled, distal end, the installer may tumble down the platform and the safety harness will exit the uncoupled end of the ledger, providing no measure of safety to the installer.
A conventional rosette 500, as seen in FIG. 10, has a central aperture 503 to receive the vertical tubing, four small openings 501 A-D to facilitate right-angled connections and four larger openings 502 A-D to facilitate connections at any angles. Typically, a vertically and horizontally slotted head 504 coupled to the end of a ledger is positioned with respect to the rosette 500 such that the horizontal slot of the head 504 is positioned over and under the rosette 500 and the vertical slot of the head is aligned with an aperture of the rosette 500. A wedge 302 is then hammered into the vertical slot (or gap) to couple the ledger 102 via the head 504 to the vertical standard 103 via the rosette 500 using, inter alia, frictional force. Note that, disadvantageously, until the wedge 302 is installed, there is significant play between the rosette 500 and head of a horizontal member giving rise to safety concerns. Furthermore, once installed, wedges often work free when workers traverse the platform. When these wedges work free, the scaffold can become unstable and collapse. Further, even if the scaffold does not collapse, steel wedges, which, as seen in the Figure, are not integrated into the head or the ledger, can fall from the scaffold injuring workers below.
Another type of modular scaffold joint uses an end connector positioned on the end of a horizontal member, where the end connector has a lip or hook section that is designed to engage or rest on a corresponding vertical connector cup or annular ring positioned on a vertical scaffold member. One such joint is disclosed in U.S. Pat. No. 4,445,307 (the Safway system scaffold) which discloses a connector 1000 positioned on a horizontal scaffold member 1001, where the connector has two vertically spaced hook sections 1003. An example of the Safway joint is shown in FIG. 5. These hook sections couple with two vertically spaced upstanding cup ring members 1102 located on the vertical scaffold member 1100. Each cup member has a surrounding annular lip 1103 to which the hook members on a horizontal member end connector engage. To lock the joint in place, the connector includes a wedge 1005 that is driven (generally by a hammer) into position below or on the underside of the lower cup member, thereby wedging the cup 1102 against the end connector hood section 1003, latching the horizontal member to the vertical member. As used herein, “latching” refers to the action of engaging a horizontal member to a vertical member, where the action of latching resists dislodgement of the horizontal member from the vertical member from an upwardly directed force.
Another cup type of latching connector is disclosed in U.S. Pat. Nos. 5,078,532 and 5,028,164 and in U.S. application Ser. No. 12/489,166, all hereby incorporated by reference (the Excel system scaffold). One embodiment of an Excel-type end connector is shown in FIG. 6. These patents and applications also have an end connector 2000 positioned on a horizontal scaffold member 2001, where the connector has two vertically spaced hooked sections 2003 that couple with two vertically spaced upstanding cup members 2102 located on the vertical scaffold member 2100. Each cup member 2102 has a terminating edge or lip section 2103 that is used to engage the hook sections 2003 on the horizontal end connector 2000. In this device, the hooked sections 2003 engage the top edge of the cup 2103, and a pivoting member or latch 2003, positioned on the horizontal end connector, is pivoted into position below the top cup member. The latch member 2003 has a distal end extending beyond the housing toward the vertical member, shaped to allow for placement of the distal end beneath a cup 2102 positioned on a vertical scaffold member. Hence, when latched, the cup 2102 is trapped between the hook engagement sections 2003 of the connector housing and the distal end of the latch member 2003. The latch pivots on a pivot pin, and can be spring loaded to bias the latch into a locking or actuated position. The latch is operated by trigger or handle 2004. Single cup embodiments are also possible, such as shown in U.S. Pat. No. 7,048,093 (hereby incorporated by reference).
What is desired is a scaffolding apparatus that is configured to couple each end of a horizontal scaffold member (also referred to herein as a horizontal, or horizontal member or a ledger) to a vertical standard (also referred to herein as a vertical member, vertical or vertical scaffold member), where the vertical member has upstanding cups, and an assembly mechanism that allows a single installer to insert and lock pivoting wedges at both ends of the horizontal member, and to release both ends substantially simultaneously if using the primary trigger, or to only release one end if using the secondary trigger.
SUMMARY
One embodiment of the invention is a horizontal scaffold member having a primary end connector and a secondary end connector. Each end connector is configured to couple to a cup on a vertical scaffold member. Each end connector includes a wedge assembly having a handle and a wedge, movable with respect to the wedge head to a latched and unlatched position. The primary wedge assembly is connected to the secondary wedge assembly by a cable, and configured so that moving the primary wedge assembly to a unlatched position also moves the secondary wedge assembly to an unlatched position.



DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention may be obtained by reference to the following Detailed Description, when taken in conjunction with the accompanying Drawings, wherein:
FIG. 1 illustrates a scaffold structure;
FIG. 2 illustrates a vertical standard;
FIG. 3 illustrates a conventional ledger with unsecured wedges;
FIG. 4 illustrates the installation of an unsecured wedge into a conventional ledger head;
FIG. 5 is a perspective view of a prior art Safway-type end connector.
FIG. 6 is a perspective view of a prior art Excel-type end connector.
FIG. 7 is a side partial cutaway view of one embodiment of the invention in a Safway-type end connector.
FIG. 8A is a side partial cutaway view of one embodiment of the invention primary end connector in the closed position.
FIG. 8B is a side partial cutaway view of one embodiment of the invention primary end connector in the open position.
FIG. 9A is a side partial cutaway view of one embodiment of the invention secondary end connector in the closed position.
FIG. 9B is a side partial cutaway view of one embodiment of the invention secondary end connector in the open position.
FIG. 10 is a prospective view of a conventional rosette.



DETAILED DESCRIPTION
As noted herein, components of the invention include at least one horizontal member which horizontal member preferably has a wedge head at each end thereof. The horizontal member is configured to engage and be supported by vertical horizontals at each end of the horizontal member. Each vertical member has at least one cup affixed in coaxial alignment thereon, the cup having an upstanding edge, lip or engagement portion for receiving an engaging hook, projecting finger or cutout located on the wedge head. The wedge head may also be referred to as a connector or end connector. The embodiments described herein show a wedge head having two engagement sections or hook sections formed in the sidewalls of the wedge head, each configured or shaped to engage corresponding lip sections on the cups on a vertical member. However, the invention is not limited to embodiments having two or more engagement sections, and can be utilized on scaffold systems where the wedge head is connectable to a single cup.
Generally, a vertical or horizontal member is a hollow tube constructed of metal, preferably galvanized metal of about 1⁄8 inch thickness. The vertical member will have a series of cups attached thereon at spaced apart locations. Each cup has an upper side and an underside, with an upstanding edge or lip section (also referred to as an engagement section) on the upper side of the cup. See generally, FIGS. 5 and 6. Each horizontal member has two ends, with a wedge head located on each end. The wedge head can be a crimped metal tube having an interior section, with suitable openings to accommodate the wedge assembly, where the crimped tube is attached at substantially right angles to the long axis of the horizontal tube (such as in the Safway design), or may compromise two substantially parallel sidewalls (suitably joined together for rigidity) and having an interior space therebetween, and also joined to the horizontal tube at substantially right angles to the long axis of the horizontal member (such as in the Excel design Ser. No. 12/489,166). As indicated, the construction features of the wedge head can vary.
One embodiment proposed for a Safway-type cup and end connector is shown in cutaway view of FIG. 7. Shown are two vertical members 800, coupled to a horizontal member 600. Each vertical member 800 has two cups 801. Each cup has an upwardly raised annular lip portion 802 (generally an annular raised rolled lip with an interior surrounding depression), and an underside 809 opposite the lip portion. Horizontal scaffold member 600 has a wedge head 601 positioned on each end of the horizontal tube, a primary wedge head 601p or primary end connector 490, and a secondary wedge head 601s or secondary end connector 390 (where the “p” represents primary and the “s” represents secondary—in most instances only a single number, e.g. “601” will be used as the two components are substantially similar in the embodiments shown, and where clarity is required, the “p” and “s” designations will be utilized). Generally, the construction of each wedge head will be substantially similar, with the exception of the cable connection discussed later. The wedge heads 601p, 601s shown are crimped hollow tubes coupled to the opposing ends of the horizontal member 600, with the interior of the horizontal member 600 communicating with the interior of the wedge heads 601. Each wedge head 601 has a hook portion 602 adapted to engage the lip section 802 of the cups 800. Contained in each wedge head 601 is a wedge head assembly 610, generally comprising a handle portion 611 (sometimes referred to as a trigger), and a wedge portion 612 connected to or integral with the handle portion 611. As shown the handle and wedge are integral, and moveable within the interior of the wedge head (such as pivotable as shown, or slidable (not shown)). Wedge head 601 has a front opening 690 facing the vertical member through which the wedge 612 can extend, and a rear opening 680 through which the handle 611 can extend.
Each wedge assembly is biased so that wedge 612 is positioned in a closed or latched position by using a biasing means, such as a spring 620. Closed or latched means that the wedge 612, when the horizontal member is coupled to a vertical member, will be positioned adjacent to the underside 809 of a cup, thereby coupling the wedge head 601 to the cup 801 in a fashion to resist removal of the wedge head by an upward force. It is not necessary that the wedge be in tight engagement with the underside of the cup, or even touch the cup underside. In some embodiments, it is preferred that the connection be loose, as the connection functions to trap the cup between the wedge and hook engagement portion on the wedge head. Biasing means can be a spring such as a bar or wire spring, coil or other suitable biasing means, and will be referred to as a spring in the following. The wedge assembly is considered “open” or “unlatched” when the wedge 612 is position away from the underside of a cup 801, so that when an upward lifting force is applied to a wedge head, the wedge head is detachable or separable from the cup (as the wedge 612 is now not in a blocking position adjacent the underside of the cup).
As shown, spring 620 has two ends, 620A and 620B, and a pivot point C. End 620A bears against a bottom plate 640 on wedge head 601, while end 620B bears against handle 611. A cable 700 (rope, chain or other flexible connector, but generally not substantially stretchable lengthwise, with a preferred embodiment being a 1⁄8 inch wire rope) runs through the hollow interior of the horizontal member 600. One end of cable 700 enters the interior of the primary wedge head 601p, and slides over a member 90p, such as a pin, pulley or other member, which may be rotatable in the wedge head interior. The cable 700 then extends downwardly and is attached to or is connected to the wedge assembly at the handle 611p. The other end of the cable 700 enters the interior of the secondary wedge head 601s (or secondary end connector 390), and slides over member 90s and then is connected to or attached to the wedge assembly at wedge 612. The members 90a and 90B may be dispensed with, but they are preferred to keep the cable 700 from binding in the respective wedge head 601.
As described, each end of the horizontal member 600 can be connected to a vertical by “snapping” the horizontal wedge head assembly into place on the cup of a vertical. In this action, the horizontal member is positioned with the top hook portion 602 clearing the raised lip 802 of a cup (the bottom hook portion will also be positioned slightly above the raised lip of the lower cup). As the wedge head 601 is moved toward the vertical, the wedge 612 will contact the side of the cup 801 and be moved to the open or unlaced position, as the spring 620 compresses. Once the hook sections 602 on the wedge head 601 is positioned directly above the raised lip 802, the wedge head 601 can be lowered until the lip sections 802 of the upper and lower cups contacts the respective upper and lower hook engagement portions 602. At this point, wedge 612 will pivot forward by spring 620 until a portion of the wedge 612 is positioned below a cup 801, thereby latching the horizontal to the respective vertical. Also, each wedge may be manually coupled to a vertical by an operator manually depressing handle 611, and then coupling the wedge head 601 to the vertical members cups, and then releasing handle 611.
As shown, the end of the cable in the primary connector or primary wedge head 601p is connected to the handle 611p in that wedge head; while the other end of the cable 700 is connected to the wedge 612s in secondary connector. As a result, as handle 601p in the primary end connector 490 is depressed and pivoted downwardly (thereby unlatching the wedge 612p head in the primary connector), the cable 700 follows the handle 611p downwardly. As a result, the wedge 612s in the secondary connector is also pivoted or pulled away from the corresponding vertical member, and the connected handle 611s compresses the respective spring 620s, thereby pivoting the secondary wedge assembly, against the spring bias, to the unlatched position. In this fashion, a single operator may thereby unlatch both wedge heads by the operation of only the primary handle 611p. 
However, if the operator operates the handle 611s on the secondary end connector 390 to open or unlatch the wedge 612s by depressing the handle 611s and pivoting the handle downwardly, such action does not open or unlatch the wedge 612p on the primary end connector 490. This occurs due to the different attachment points of the cable 700 to the primary and secondary wedge assemblies. The act of operating the secondary connector handle 611s will not result in the spring 620p in the primary wedge head being compressed as there is no force exerted on the primary spring in response to operation of the handle 611s in the secondary connector. Preferably, the two handles 611p and 611s should be shaped differently (not shown) so that an operator may easily distinguish the primary end connector from the secondary end connector.
Another embodiment of the invention for use with an Excel-type connector and cup is shown in FIGS. 8 and 9. FIGS. 8A and 8B shows an end connector designed to accommodate an Excel-type cup having an upstanding lip that is the edge of the cup. Construction details of this wedge head and the cups that correspond are contained in U.S. Pat. Nos. 5,078,532 and 5,028,164 and in U.S. application Ser. No. 12/489,166. The primary differences of this embodiment from that shown in FIG. 7, are: (1) the location of the spring 620—in this embodiment, one end of the spring 620A bears against a pin in the interior of the wedge head, and the other end of the spring 620B bears against the wedge 612 (as opposed to the handle in the embodiment of FIG. 8); (2) the cable 700 connects on the secondary wedge assembly to a rear projecting extension 900 shown integrally attached to the wedge 612s (shown in FIG. 9A and 9B, the rear extension allows the cable attachment point to be raised on the wedge assembly); and (3) the primary wedge 612p and secondary wedge 612s are not shaped identically as only the secondary wedge, as shown, has a reward extension 900. However, both primary and secondary wedges can have the reward extension. Also, as shown the primary and secondary handles 611p and 611s are shaped differently to allow an operator to easily tell them apart.
In each embodiment, operation of the primary latch or connector exerts a force on the secondary end connector, transmitted through the increased cable tension cable—as the cable is drawn downward in the primary connector, the other end of the cable is drawn toward the primary end connector by the tension in the cable. As the wedge is connected to the cable, the wedge is thus drawn to the unlatched position. Contra wise, as the secondary latch is dawn downward to unlatch the secondary connector, the cable's tension is lessened on the primary connector, and hence no forced is exerted to counterbalance the tension of the spring in the primary end connector.
To install, the cable (such as a 1⁄8′′ wire rope) is installed by first attaching it to the rearward extension 900 of the wedge with a crimp-able wire rope sleeve. The wedge assembly is then installed in the interior of the secondary wedge head (e.g. the trigger (handle)), spring and bolt to the secondary end connector. At this point, the wire rope cable is pushed through the secondary wedge head and into the horizontal tubing member towards the primary end connector. The cable is captured at the primary wedge head and pulled through the primary wedge head. The primary wedge assembly and spring and sleeve bushing are joined to the primary wedge head. The primary handle (trigger) is then rotating downwardly to the unlatched position, then attach the wire rope cable to the primary handle or trigger using a crimpable wire rope sleeve. The connector can also be used with rosettes as described in the provisional application.
To those skilled in the art to which this invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined herein and in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. The embodiments shown and described above are only exemplary. Even though numerous characteristics and advantages of embodiments of the invention have been set forth in the foregoing description together with details of the invention, the disclosure is illustrative only and changes may be made within the principles of the invention to the full extent indicated by the broad general meaning of the terms used herein. For example, the concepts described herein for coupling horizontal members to vertical members can be used to couple bracing members to vertical members or to horizontal members. Coupling includes, but is not limited to attaching, engaging, mounting, clamping, welding, bolting and components used for coupling include bolts and nuts, rivets, clevis, latches, clamps, welds, screws, rivets and the like. The vertical member can have any number of coaxially cups attached thereto, the vertical spacing of such cups being any such distance as is suitable for the intended use. The method includes a method of disconnecting both ends of a horizontal scaffold member from a vertical scaffold member.

## Claims

1. A horizontal scaffold member comprising:
a tubular member and a primary wedge head attached to one end of the member and a secondary wedge head attached to the opposite end of the member, said primary and secondary wedge heads having an engagement portion configured to couple to a cup on a vertical scaffold member where said cup has a cup underside,
said primary and secondary wedge heads further comprising a respective primary wedge assembly and a secondary wedge assembly, each of said wedge assemblies comprising a wedge and a coupled handle partially positioned within each respective wedge head, each said wedge assembly moving in said respective wedge head from a latched to an unlatched position, wherein in said latched position, when said tubular member is coupled to a vertical scaffold member, said wedge is positioned adjacent to a cup underside on said vertical scaffold, and in a unlatched position, said wedge is positioned away from said cup underside on a vertical member;
a cable connecting said primary wedge assembly to said secondary wedge assembly, said primary wedge assembly and said secondary wedge assembly both moving to said unlatched position when said primary wedge is moved from a latched to an unlatched position; and when said secondary wedge assembly is moved to said unlatched position, said primary wedge assembly remains in said latched position.

2. The horizontal scaffold member according to claim 1 wherein said primary wedge head and secondary wedge heads each have two vertically spaced apart engagement portions.

3. The horizontal scaffold member according to claim 2 wherein said engagement portions each comprise a hook section.

4. The horizontal scaffold member according to claim 1 wherein said wedge head assemblies are pivotable in said wedge head.

5. The horizontal scaffold member according to claim 1 further comprising a rotatable member mounted in said primary wedge head and said cable rotating on said rotatable member when said primary wedge head assembly is moved from a latched to unlatched position.

6. The horizontal scaffold member according to claim 1 wherein said cable is attached to said primary wedge head assembly at said handle of said wedge head assembly, and wherein said cable is attached to said secondary wedge head assembly at said wedge of said secondary wedge head assembly.

7. The horizontal scaffold member according to claim 1 wherein said cable is attached to said primary wedge head assembly at said wedge of said primary wedge head assembly, and wherein said cable is attached to said secondary wedge head assembly at said handle of said secondary wedge head assembly.

8. A horizontal scaffold member according to claim 1 wherein said primary and said secondary wedge head assemblies are biased to said latched position.

9. The horizontal scaffold member of claim 8 wherein said cable is a wire rope.

10. A method of unlatching a horizontal scaffold member, where said horizontal scaffold member has two opposed ends, and an end connector positioned on each of said opposed ends, each of said end connectors being latched to a separate vertical scaffold member at a coupling point, where each of said latched end connectors resists removal from said corresponding vertical member from an applied upward force, each of said end connectors having a wedge assembly, each of said wedge assemblies joined together by a flexible cable, one of said wedge assemblies having a primary latch member that when operated, moves both end connectors to an unlatched state, and the other of said wedge assemblies having a secondary latch member that when operated, moves only said second latch member to an unlatched state; said method comprising the step of
either (a) operating one of said wedge assemblies to unlatch both of said end connectors from said respective vertical scaffold members, whereby said unlatched end connectors may be removed from said corresponding vertical scaffold member by an upward force, or (b) operating the other of said wedge assemblies to unlatch only said other wedge assembly from said respective vertical scaffold members, whereby said unlatched end connector may be removed from said corresponding vertical scaffold member by an upward force.