Patent Publication Number: US-8992111-B2

Title: Components to allow buckets to be used as structural or alternative elements

Description:
RELATED APPLICATION 
     This application is being filed on 30 Sep. 2010, as a PCT International Patent application in the name of Primordial Soup, LLC, a U.S. national corporation, applicant for the designation of all countries except the U.S., and Tim Bachman, a citizen of the U.S., Matthew Vail Leyden, a citizen of the U.S., Christian Richard Trifilio, a citizen of the U.S., Jeff Waffensmith, a citizen of the U.S., and Rod St. Michel, a citizen of the U.S., applicants for the designation of the U.S. only, and claims priority to U.S. Patent Application Ser. No. 61/247,337 filed on 30 Sep. 2009. 
    
    
     BACKGROUND 
     The five-gallon bucket is a common item at construction sites, garages, and in the backs of pickup trucks all over the country. Originally intended to ship bulk quantities of food for the foodservice industry or bulk quantities of spackling etc. for the construction industry, people have found that there are several additional Uses for the buckets. Such uses include using them to hold paint to use with a roller to holding bait for fishing. The result is that these buckets are readily available at home improvement stores to purchase as well as there being a large volume of buckets in the field that have been re-purposed and are being re-used after their initial use has expired. 
     The five-gallon bucket, although thin and made of plastic, is a relatively strong component that can easily support a 200 plus pound man sitting on top of it. In addition, the buckets are light-weight, stackable, and store easily. 
     SUMMARY 
     The disclosure relates to a set of connectors that connect buckets, such as five gallon buckets, to each other, to the ground, to dimensional lumber and/or to pipe for the purpose of producing objects such as benches, stepstools, tables, sawhorses, shelters, platforms, etc. 
    
    
     
       DESCRIPTION OF THE FIGURES 
         FIG. 1  shows two buckets connected by an example connector. 
         FIG. 2  shows a cross-section of a portion of the buckets and the connector of  FIG. 1 . 
         FIG. 3  shows two buckets connected by an example connector. 
         FIG. 4  shows a cross-section of a portion of the buckets and the connector of  FIG. 3 . 
         FIG. 5  shows a top perspective view of the example connector of  FIG. 1 . 
         FIG. 6  shows a side view of the connector of  FIG. 5 . 
         FIG. 7  shows an end view of the connector of  FIG. 5 . 
         FIG. 8  shows another top perspective view of the connector of  FIG. 5 . 
         FIG. 9  shows a top view of the connector of  FIG. 5 . 
         FIG. 10  shows a bottom perspective view of the connector of  FIG. 5 . 
         FIG. 11  shows a bottom view of the connector of  FIG. 5 . 
         FIG. 12  shows a bucket with the connector of  FIG. 5  and boards extending therefrom. 
         FIG. 13  shows two buckets with the connectors of  FIG. 5  with boards extending therebetween. 
         FIG. 14  shows a bucket with the connector of  FIG. 5  and boards extending therefrom. 
         FIG. 15  shows the bucket, connector, and boards of  FIG. 14 . 
         FIG. 16  shows another example connector. 
         FIG. 17  shows other example connectors connected to a bucket. 
         FIG. 18  shows other example connectors connected to a bucket. 
         FIG. 19  shows one of the connectors of  FIG. 18 . 
         FIG. 20  shows one of the connectors of  FIG. 18 . 
         FIG. 21  shows the connector of  FIG. 20 . 
         FIG. 22  shows two buckets connected by another example connector. 
         FIG. 23  shows a plurality of buckets connected by a plurality of connectors. 
         FIG. 24  shows a bucket with an example stabilizing base connector. 
         FIG. 25  shows a bucket with an example leveling base connector. 
         FIG. 26  shows a bucket with another example base connector with spikes. 
         FIG. 27  shows a bucket with an example variable angle base connector. 
         FIG. 28  shows a bucket with an example vertical lumber connector. 
         FIG. 29  shows a bucket with an example joist hanger connector. 
         FIG. 30  shows a bucket with another example connector. 
         FIG. 31  shows a bucket with an example vertical pipe connector. 
         FIG. 32  shows a bucket with an example horizontal pipe connector. 
         FIG. 33  shows a bucket with another example connector. 
         FIG. 34  shows a bucket with another example connector. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure relates to connectors that couple five gallon buckets to each other, to the ground, to dimensional lumber and/or to pipe for the purpose of producing useful objects such as benches, stepstools, tables, sawhorses, shelters, and platforms. 
     By using the connectors described herein, the buckets can do the same jobs as traditional sawhorses, concrete blocks, metal scaffolding, and workmate-style benches, as well as have additional utility. 
     The connectors themselves may be primitive devices that perform a single function or may be composite devices that can perform more than one primitive function. The primitive devices include bucket-to-bucket connections, bucket-to-ground connections, bucket-to-lumber connections and bucket-to-pipe connections and connector-to-connector connections. 
     The example connectors disclosed herein work by allowing a user to do one or more of the following, while still retaining the integrity of the bucket. In some examples, this can be accomplished without tools or modifications needed to the buckets themselves. 
     Examples of such uses include:
         attach two buckets to each other either top to bottom, top to top bottom to bottom or side to side;   attach a bucket to plywood or sheathing;   attach a bucket to flat ground securely;   attach a bucket to uneven ground;   attach a bucket to dimensional lumber such as a 2×4; and   attach a bucket to pipe easily such as 4″ diameter PVC pipe.       

     With the ability to make the above connections quickly, the users can create structural elements that can be configured intuitively and quickly to build a variety of elements that could include:
         short or tall workbench or table;   scaffolding;   stage;   wood stacking platform;   sawhorses—infinitely adjustable in length and width;   portable step up for painting;   garage/work-site shelves;   bench;   work hammock;   non-flat storage;   scaffold on a hill or incline;   tarp tent to cover boats etc.;   green house cover for gardens;   soccer/sports goals;   work light supports;   temporary shelters;   volleyball net;   scaffolding adapted to stairs; and   bridge (e.g., to cross a body of water, like a creek).
 
The connectors can be sold in kits that allow the connectors to be used to assemble different structures.
       

     In addition to the above, the buckets can be filed with rocks, water, sand, etc., to add stability. The buckets can also still be used to hold tools, lights, screws, etc. when used alone or structurally, as shown in several of the figures. 
     Example configurations are reflected in  FIGS. 1-34 . These figures reflect the multiple different configurations that could be used to create the connector. Some examples are:
         a solid “ring” that the bucket snaps into that facilitates connecting the buckets and structural elements—see, e.g.,  FIGS. 5-11  and  16 ; and   “stick” or “block” shaped elements that attach to the bucket bottom or top that can be used alone or can be attached to additional “sticks” to create additional utility—see, e.g.,  FIGS. 17-21 .       

     Referring now to  FIGS. 1 and 2 , there are many methods by which a connector can be attached to a bucket. One method of attachment is to snap the connector on in the same manner that a bucket lid snaps on. Since the bucket has a slight taper, the connector can be press fit into place on the bucket. Additionally, latches, straps, screws, etc. could be used. 
     In  FIG. 1 , a first five gallon bucket  110  is coupled to a second, inverted bucket  112  using a connector  120 . Generally, the connector  120  engages each of the buckets  110 ,  112  similar to that of a lid to couple the connector  120  to each of the buckets  110 ,  112 . 
     As shown in  FIG. 2 , the connector  120  includes a groove  115  into which an open end surface  114 ,  116  of each of the buckets  110 ,  112  can be inserted to form a structure  100 . A lip  122  formed by the connector  120  engages the surface  114  of the bucket  110  to connect the bucket  110  to the connector  120 . 
     In this example, the structure  100  can be used for many of the applications described above, such a scaffolding, part of a sawhorse, etc. 
     For example, as shown in  FIGS. 3 and 4 , a structure  200  is created with the bucket  112  inverted so that a closed end  118  of the bucket  112  is connected to the connector  120 . Member  124  formed by the connector  120  engages an outer surface  119  of the closed end  118  to connect the bucket  112  to the connector  120 . 
     Referring now to  FIGS. 5-11 , the connector  120  is shown in isolation. The connector  120  includes several features that allow the connector  120  to be used in a variety of contexts. The connector  120  is one example of a composite device capable of performing more than one primitive function. 
     The connector  120  has a first connector side  111  and a second connector side  113 . The connector  120  includes two parallel slots  210 ,  212  formed by protrusions  202 ,  203 ,  204 ,  205 ,  206 ,  208  for holding a cross member, such as a piece of 2×4 dimensional lumber of any length, securely in the horizontal orientation (with the 4″ dimension parallel to the ground). Tabs  222  are formed on protrusions  206 ,  208  and extend into the slots  210 ,  212  to capture the lumber to couple the lumber to the connector  120 . Relief apertures  223  are formed behind the tabs  222  within the protrusions  206 ,  208  to allow the tabs  222  to flex so that the lumber can be “snapped in” to the slots  210 ,  212  easily yet contain the lumber securely once in place. In other words, the relief apertures  223  allow the tabs  222  to “flex” so the tabs  222  can move out of the way to let the board pass into and out of the slots  210 ,  212 . 
     In addition, dimples  233  are formed to allow for the connector  120  to snugly grip dimensional 2×4 lumber with varying widths due to normal manufacturing variations, moisture content, etc. 
     For example, as shown in  FIGS. 12 and 13 , boards  310 ,  312  and  314 ,  316  are connected to connectors  120 . The boards  310 ,  312 ,  314 ,  316  can be coupled and uncoupled from within the slots  210 ,  212  by sliding the boards into the slots  210 ,  212  so that the tabs  222  engage the boards. 
     Referring again to  FIGS. 5-11 , the connector  120  also includes a center slot  240  formed by protrusions  202 ,  203 ,  204 ,  205 ,  206 ,  208  for holding a cross member, such as a 2×4 piece of dimensional lumber of any length securely in the vertical orientation (with the 4″ dimension perpendicular to the ground). In the example shown, the center slot  240  is oriented perpendicular to the slots  210 ,  212 , although other orientations can also be used. 
     The connector  120  also includes recesses  250 . The recesses  250  allow a fastener, such as a screw or nail, to be placed to securely connect the lumber to the connector  120 . 
     Other configurations are possible. For example, lumber of different sizes (e.g., 2×6, 4×6, etc.) can be accommodated by the connector  120 . In addition, the orientation and size of the slots can be modified, as described further below. 
     The second connector side  113  of the connector  120  also includes grooves  262  formed in an extension member  264 . The grooves  262  are sized to receive horizontal pipes extending across the connector  120 . See, e.g.,  FIG. 32 . In addition, the connector  120  includes a groove  266  into which the open end surface  114 ,  116  of each of the buckets  110 ,  112  can be inserted to couple the buckets to the connector  120 . A diameter of an inner surface  268  of the connector  120  is sized to engage the closed end  118  of the bucket  112  to form an interference fit. 
     For example, referring now to  FIGS. 14 and 15 , a connector  420  is shown. The connector  420  includes protrusions  422 ,  424 ,  426  that allow two 2×4 boards  410 ,  412  to be connected to the connector  420  in a cross configuration. Other embodiments are possible. 
     In these examples, the connectors  120 ,  420  can be configured to be connected to the top or bottom of the buckets  112 ,  114  while maintaining the structural and watertight integrity of the buckets. Heavy weight (water, rocks, screws, tools etc.) can be added to the buckets  112 ,  114  before the connector  120  is attached to add stability to the structure being built. 
     In other examples, the connectors can be ring-shaped or have alternative shapes. 
     In  FIG. 16 , a ring-shaped connector  500  is shown. The connector  500  includes a groove  502  formed on each side of the connector  500  so that one or two buckets can be coupled to the connector  500 . In addition, the connector  500  forms opposing slots  504  on each side of the connector  500  so that a cross member, such as a 2×4 board, can be extended through the slots  504  to build structures. 
     The connectors need not be ring-shaped. Rather, single blocks, rectangular shapes or organic forms can be equally effective. 
     For example, a single connector block can be connected to a bucket alone or in pairs to control connection of the bucket to another bucket and/or the placement of lumber or pipe. For example, as shown in  FIG. 17 , connector blocks  510  are coupled at periodic intervals (e.g., at 90 degree intervals) along the open end surface  116  of the bucket  112 . Each of the connector blocks  510  defines grooves  512  in both sides of the blocks  510  to allow the blocks  510  to be coupled to the bucket  112 . 
     In another example shown in  FIGS. 18-21 , rectangle connectors  530 ,  540  are configured to span the bucket diameter to control lumber and/or connect buckets together. 
     The connector  540  includes opposing side members  541  forming grooves  542  that are positioned to engage the open end surface  116  of the bucket  112 . A cross-member  544  spans between the two side members  544 . The connector  530  similarly includes side members  541  forming grooves  542 . In addition, the cross-member  546  spanning between the side members  541  includes a slot to accept the cross-member  546  of the connector  540  when positioned at a 90 degree angle with respect to one another. 
     The rectangular shape of the connectors  530 ,  540  spans the bucket diameter with efficiency and can be used to control lumber or pipe singly or in pairs. 
     In the examples shown, any lumber coupled to the connectors  530 ,  540  intersects at right angles above the bucket. However, in alternative applications, angles less than or greater than ninety degrees may be used. 
     With the ability to make the above connections quickly, the users can create structural elements that can be configured intuitively and quickly to build a variety of useful structures. 
     For example, bucket to bucket connections allow one bucket to be joined to another so that they may be stacked. Bucket to bucket connections exist in four general forms: lid-to-lid ( FIGS. 1-2 ), base-to-base (see connector  600  shown in  FIG. 22 ), lid-to-base ( FIGS. 3-4 ), and side-to-side. 
     As shown in  FIG. 23 , side-to-side connectors  650  connect buckets, not along the axis of the bucket as in the previously described connectors, but radial to the axis of the bucket, either with the lid ends facing the same direction or in opposite directions. These connectors  650  attach to the buckets in a manner consistent with the other connectors and attach to the adjacent connectors  650  by snaps. The connectors  650  are generally square, but other geometric shapes (such as triangles, hexagon etc.) could be used as well. The connectors  650  can be used for building walls or storage bins, and can be made with lids and without. 
     Referring now to  FIGS. 24-27 , bucket-to-ground connections improve the interface between the bucket and the earth, floor, sidewalk, or street, etc. Bucket-to-ground connections exist in four general forms: stabilizing base, leveler, spiked, cushioned, wheeled or weighted bases, and variable angle base. 
     As shown in  FIG. 24 , a stabilizing base  710  includes an aperture  712  sized to receive a closed or open end of the bucket  112 . The stabilizing base  710  is a connector that can be attached to either end of the bucket  112  to enlarge the footprint and add stability to the construct. 
     As shown in  FIG. 25 , a leveling base  720  is a two-part connector that allows a bucket column  722  to be raised or lowered in directions  724  relative to the ground. One side  726  of the base  720  connects to the bucket  112 , while the other side  728  translates within that part and locks in continuous or discreet positions, effectively increasing or decreasing the distance from the bucket  112  to the ground. One translation mechanism is a large thread, although bayoneting or pinning the translating part into discreet positions could also be used. 
     Spiked, cushioned, wheeled, and/or weighted bases include special interfaces with the ground. It may be desirable to have bases with a cushioned, non-marring surface, or non-slip surface when working in doors. Alternatively, it may be desirable to have a spiked surface or a surface through which one may drive spikes for securing the construct when working on grass or dirt. Adding casters for mobility or weight in the form of sand, water or metal may also add utility. 
     For example, referring now to  FIG. 26 , a connector  740  includes a plurality of spikes  742  extending from the connector. The spikes  742  can be driven into a surface, such as dirt, to stabilize the connector  740  and attached bucket  112 . The connector  740  can also include holes for driving stakes through the connector  740  and into the ground. 
     In  FIG. 27 , a variable angle base  750  is used to level a construct on uneven ground. The base  750  includes a first part  752  that attaches to the bucket  112  and a second part  754  that rotates at an angle  758  relative to the first part  752  and interfaces with the ground. The second part  754  can rotate freely or be fixed in place at a discreet angle. 
     Bucket-to-lumber connections connect a bucket to dimensional lumber or sheathing. Types of bucket-to-lumber connections include: lumber-on-end, lumber-on-side, lumber vertical, joist hanger, and sheathing. 
     Examples of the lumber-on-end and lumber-on-side configurations are shown in  FIGS. 12-15 . Other configurations are possible. 
     A vertical lumber connector  810  is shown in  FIG. 28 . The connector  810  allows the use of dimensional lumber  812  as a post, and the bucket  112  becomes a stable base for the post. The lumber  812  slides through an aperture  811  in the connector  810  and rests on the bottom of the bucket  112 . Stability can be added by filing the bucket  112  with sand or gravel and by securing the post to the connector  810  with a fastener, such as a screw or clamp. 
     Referring now to  FIG. 29 , a joist hanger bucket connector  820  includes a pocket  822  positioned below the open end surface  116  of the bucket  112 . This allows the dimensional lumber  824  to be suspended from the side of the bucket  112  rather than pass the lumber  824  over the top of the bucket  112 . This allows one to link one bucket column to another using lumber to add stability to the construct. 
     Plywood/sheathing connectors function similarly to dimensional lumber connectors, with the difference being the thickness of the board being accommodated. For example, in one alternative embodiment shown in  FIG. 30 , a connector  832  includes disks  833  that engage a bottom surface of a plywood sheet  834 . The disks  833  have a roughened or sticky top surface that minimizes any tendencies of the sheet  834  to slip. 
     Bucket-to-pipe connections connect a bucket to a pipe. Types of bucket-to-pipe connections include vertical pipe and horizontal pipe. In some examples, pipe can include conduit through which a fluid could flow, as well as the handle of a rake or shovel, etc. 
     Referring to  FIG. 31 , a vertical pipe connector  910  allows one to use a pipe  914  as a post, and the bucket  112  becomes a stable base for the post. The pipe  914  slides through an aperture  912  formed in the connector  910  and rests on the bottom of the bucket  112 . Stability can be added by filing the bucket  112  with sand or gravel and by securing the post to the connector  910  with a fastener, such as a screw, clamp or adhesive. 
     Referring to  FIG. 32 , a horizontal pipe connector  920  allows one to attach pipes  924  to the bucket  112  in a horizontal orientation. One side of the connector  920  connects to the bucket  112 , and the other side receives the pipes  924 . The pipes  924  can rest within a semi-circular groove  922  formed in the connector  920 , snap in place or be slipped into a cylindrical receiver. 
     In some cases, it may be advantageous to connect bucket connectors to each other in order to support modularity or add degrees of freedom. Methods for achieving this may include threaded connections, snaps, latches, etc. 
     There are many methods by which the lumber can be captured by the connectors. The lumber can snap into place, latch in, be secured by fasteners (i.e. screws, nails), straps or adhesive, or enveloped by a connector  930 , as shown in  FIG. 33 . The connector  930  defines two apertures  932 ,  934  through which 2×4 boards  936 ,  938  extend. 
     Referring to  FIG. 34 , another effective method of securing lumber  958 ,  959  to the bucket  112  is a connector  950  including a first part  952  that forms slots for the lumber  958 ,  959 . A middle portion  956  of the connector  950  includes a second part  954  that rotates 90 degrees to capture (as shown) and release the lumber  958 ,  959 . 
     Various embodiments are described above. These embodiments are examples only. Other variations are possible, and features of different embodiments can be combined to form other variations.