Patent Publication Number: US-7584824-B2

Title: Scaffold plank with end connector and method of making same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   The present application is a continuation of U.S. patent application Ser. No. 11/246,946 entitled SCAFFOLD PLANK WITH END CONNECTOR AND METHOD OF MAKING SAME filed Oct. 7, 2005 now U.S. Pat. No. 7,188,707 which is a continuation of U.S. patent application Ser. No. 10/656,818 entitled SCAFFOLD PLANK WITH END CONNECTOR AND METHOD OF MAKING SAME filed Sep. 5, 2003 and issued as U.S. Pat. No. 7,090,053 on Aug. 15, 2006, which is a continuation-in-part of U.S. application Ser. No. 10/147,792 entitled SCAFFOLD PLANK AND METHOD OF MAKING SAME filed May 17, 2002 and now abandoned, which is a continuation of U.S. application Ser. No. 09/614,079 entitled IMPROVED SCAFFOLD PLANK AND METHOD OF MAKING SAME filed Jul. 11, 2000 and issued as U.S. Pat. No. 6,431,316 on Aug. 13, 2002, which claims priority to U.S. Provisional Application Ser. No. 60/143,535 entitled IMPROVED SCAFFOLD PLANK AND METHOD OF MAKING THE SAME filed Jul. 13, 1999. 

   STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
   Not Applicable 
   BACKGROUND OF THE INVENTION 
   The present invention relates generally to scaffolding systems, and more particularly to a scaffold plank fabricated from a plastic material and optionally including end connectors which are configured to facilitate the firm engagement of the plank to a support frame structure. 
   As is well known in the building industry, scaffolding is virtually always employed during various facets of exterior and/or interior building construction or refurbishment. Known scaffolding systems typically comprise steel support frame structures which are selectively engageable to each other in a stacked fashion for achieving a desired overall height. In addition to the support frame structures, the scaffolding system includes a multiplicity of elongate scaffold planks, each of which is horizontally extensible between a respective pair of the support frame structures. The prior art scaffold planks are most typically fabricated from wood. Indeed, the use of wood for the prior art scaffold planks has been a long standing tradition in the building industry 
   Though wood scaffold planks have been and continue to be generally suitable for use in scaffolding systems, the use of wood for the scaffolding planks gives rise to certain shortcomings and deficiencies which detract from their overall utility. More particularly, scaffold planks fabricated from wood are susceptible to splitting as well as to dry rot. Additionally, when exteriorly used scaffolding systems are subjected to rain or thunder storms as often occurs, the resultant water soaking of the wood scaffold planks virtually doubles their weight as compared to when dry, thus substantially increasing the difficulty by which they are moved or otherwise manipulated. Such water soaking of the wood scaffold planks also often results in the warping or twisting thereof. As will be recognized, due to their susceptibility to splitting, dry rot and warping/twisting, the prior art wood scaffold planks have a reasonably limited life span and require moderately frequent replacement. 
   Another drawback associated with the use of wood scaffold planks is the common occurrence of scaffold setters experiencing splinters in their hands when working with the same. Indeed, occurrences of splinters can reach a level of severity resulting in the initiation of a workers compensation claim. Moreover, because nails are also often used in conjunction with wood scaffold planks, workers are more susceptible to being injured by nails which are left there within. 
   A further problem associated with the use of wood scaffold planks is the relatively high cost thereof attributable to diminishing supplies of lumber. Indeed, ongoing extensive worldwide deforestation and the related environmental and ecological problems has, in addition to resulting in increases in the price of lumber, stimulated a movement to adopt lumber alternatives for purposes of contributing to the conservation and restoration of forests. These diminishing supplies of lumber also frequently give rise to delays in the delivery of lumber raw material to those mills which manufacture wood scaffold planks, thus resulting in periodic problems in meeting the supply demands of the building industry. Though metal (e.g., aluminum) scaffold planks have been developed in the prior art as an alternative to wood planks, such aluminum planks are extremely costly. Additionally, both the wood and aluminum scaffold planks of currently known scaffolding systems lack connectors which are suited to allow the plank to be quickly and easily engaged to a support frame structure. 
   The present invention addresses these concerns by providing a scaffold plank which is manufactured or fabricated from a plastic material and may optionally be provided with end connectors which are specifically sized and configured to facilitate the quick and easy interface of the plank to a scaffolding system support frame structure. As will be discussed below, the plastic scaffold plank of the present invention, though possessing the same level of structural integrity or rigidity as the prior art wood scaffold planks, does not have the same susceptibility to splitting, dry rot or warping/twisting. Additionally, the weight of the scaffold plank of the present invention is the same whether wet or dry. The use of plastic for the scaffold planks of the present invention also eliminates occurrences of splinters, and substantially eliminates injuries potentially caused by nails left therein. Further, since the scaffold planks of the present invention may be fabricated from recycled/recyclable plastic material, they address the need of recycling used plastic into a useful product, in addition to satisfying the increasing desire in industry for lumber alternatives. These, and other features of the present invention will be described in more detail below. 
   BRIEF SUMMARY OF THE INVENTION 
   In accordance with the present invention, there is provided a scaffold plank assembly for engagement to a scaffolding frame. The scaffold plank assembly comprises an elongate, non-metal plank which defines opposed first and second ends and at least one interior cavity. Attached to respective ones of the opposed ends of the plank is a pair of end connectors. The end connectors each comprise a main body defining an arcuate engagement surface, and at least two arms which are attached to the main body. Each of the arms defines an arcuate engagement surface which is substantially continuous with the body engagement surface. Attached to and extending from the main body is at least one attachment finger which is extensible into the interior cavity of the plank. The body and arm engagement surfaces are sized and configured to be cooperatively engageable to the scaffolding frame. 
   In addition to the arcuate body engagement surface, the main body includes at least two notches formed therein. The notches are sized and configured to receive respective ones of the arms of another end connector in a nesting fashion, thus allowing the end connectors of two adjacent scaffold planks to be cooperatively engaged to a common support bar of the scaffolding frame. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These, as well as other features of the present invention, will become more apparent upon reference to the drawings wherein: 
       FIG. 1  is a top perspective view of a scaffold plank constructed in accordance with a first embodiment of the present invention; 
       FIG. 1A  is a partial bottom perspective view of the scaffold plank shown in  FIG. 1 , illustrating the optional inclusion of a frame setting notch in the underside thereof; 
       FIG. 2  is a partial top perspective, cut-away view of the scaffold plank constructed in accordance with the first embodiment of the present invention, illustrating its end cap as being exploded from the main body thereof; 
       FIG. 2A  is a front perspective view of the end cap of the scaffold plank of the first embodiment of the present invention, the rear perspective view of the end cap being shown in  FIG. 2 ; 
       FIG. 3  is a partial top perspective, cut-away view of a scaffold plank constructed in accordance with a second embodiment of the present invention; 
       FIG. 4  is a partial bottom perspective, cut-away view of the scaffold plank shown in  FIG. 3 , illustrating its bottom cover as being exploded from the main body thereof; 
       FIG. 5  is an exploded view of a scaffold plank constructed in accordance with a third embodiment of the present invention, and the end connector used in conjunction therewith: 
       FIG. 6  is a cross-sectional view of the end connector shown in  FIG. 5 , further illustrating the manner in which the end connector is engaged to a segment of a support frame structure; 
       FIG. 7  is a top perspective view of a steel reinforcement plate of the end connector shown in  FIGS. 5 and 6 ; 
       FIGS. 8 and 9  are top perspective views illustrating the manner in which the scaffold planks of the third embodiment including the end connectors shown in  FIGS. 5-7  are interfaced to a support frame structure; and 
       FIG. 10  is a perspective view illustrating the manner in which scaffold planks of the third embodiment and the corresponding end connectors may be interfaced to a support frame structure in side-by-side relation, and further illustrating an optional corner connector which may be used in conjunction with the scaffold planks of the third embodiment. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same,  FIG. 1  perspectively illustrates a scaffold plank  10  constructed in accordance with a first embodiment of the present invention. The scaffold plank  10  has an elongate, generally rectangular configuration and includes a main body  12  which defines opposed ends. Attached to the respective ones of the opposed ends of the main body  12  is a pair of identically configured end caps  14 , the precise structural attributes of which will be described in more detail below. In the first embodiment, the preferred height or thickness of the scaffold plank  10  is in the range of from about 1.0 inch to about 2.50 inches, and is preferably about 1.50 inches. The preferred width of the scaffold plank  10  is in the range of from about 6.0 inches to about 15.0 inches, and is preferably about 9.50 inches. The overall length of the scaffold plank  10  (including the main body  12  and end caps  14 ) is variable. In this respect, it is contemplated that the scaffold plank  10  may be provided to have an overall length of either 6 feet, 9 feet, 12 feet, or 16 feet. However, those of ordinary skill in the art will recognize that the scaffold plank  10  of the present invention may be fabricated to have length, width, and/or height dimensions differing from those described above. 
   As seen in  FIGS. 1 and 1A , the scaffold plank  10  may be provided with two pairs of pre-formed nail holes  16 , with each pair of the nail holes  16  being disposed within the body  12  in relative close proximity to a respective one of the end caps  14 . In addition to the nail holes  16 , the main body  12  of the scaffold plank may be formed to include a spaced pair of arcuately contoured, concave frame setting notches  18  in the underside or bottom surface  20  thereof. As will be described in more detail below, the nail holes  16  and/or frame setting notches  18 , if included, are preferably formed in the main body  12  via finishing operations conducted subsequent to the fabrication of the main body  12 . The nail holes  16  and/or frame setting notches  18  are used to facilitate the engagement or interface of the scaffold plank  10  to a conventional steel frame support structure of a scaffolding system. 
   Referring now to  FIGS. 2 and 2A , the main body  12  of the scaffold plank  10  itself comprises a top wall  22  which defines a top surface  24 , a bottom wall  26  which defines the bottom surface  20 , and an opposed pair of longitudinally extending sidewalls  28  which are integrally connected to the top and bottom walls  22 ,  26 . Integrally connected to and extending perpendicularly between the top and bottom walls  22 ,  26 , and in particular the inner surfaces thereof, are five (5) reinforcement webs  30 . The reinforcement webs  30  extend in generally parallel relation to each other, thus defining six (6) compartments of cavities which extend longitudinally within the interior of the main body  12 . In the scaffold plank  10 , the preferred thickness of the top, bottom and sidewalls  22 ,  26 ,  28  and reinforcement webs  30  is approximately 0.1875 inches. 
   As further seen in  FIG. 2 , formed on the inner surface of the top wall  22  and extending longitudinally therealong in spaced, generally parallel relation to each other are seven (7) ribs  32 . Similarly, formed on and extending longitudinally along the inner surface of the bottom wall  26  in spaced, generally parallel relation to each other are seven (7) ribs  34  which are disposed in opposed, aligned relation to respective ones of the ribs  32 . The ribs  32 ,  34  extend generally perpendicularly from the inner surfaces of the top and bottom walls  22 ,  26 , respectively. In the scaffold plank  10 , the top, bottom and sidewalls  22 ,  26 ,  28  and ribs  32 ,  34  extending within the outermost pair of cavities collectively form a pair of slots which are each adapted to accommodate an elongate, rectangularly configured reinforcement bar  36 . The centermost pair of ribs  32 ,  34 , top and bottom walls  22 ,  26 , and centermost reinforcement web  30  also collectively define a slot which is adapted to accommodate a third reinforcement bar  36 . The four remaining ribs  32  and four remaining ribs  34  collectively define two more slots which extend within respective ones of those cavities disposed adjacent the outermost pair and are adapted to accommodate two additional reinforcement bars  36 . In the scaffold plank  10 , the reinforcement bars  36  are each preferably fabricated from steel having a thickness of approximately 0.1875 inches. 
   In the scaffold plank  10  shown in  FIG. 2 , three (3) reinforcement bars  36  are depicted as being disposed within respective ones of the five (5) slots extending within the interior of the main body  12 . Those of ordinary skill in the art will recognize that no reinforcement bars  36  need to be provided within the main body  12 , and that less than three or up to five reinforcement bars  36  may be included therein. The number of reinforcement bars  36 , if any, included in the interior of the main body  12  of the scaffold plank  10  is dependent upon the level of structural integrity or rigidity desired in relation thereto. In the scaffold plank  10 , each of the reinforcement bars  36  is preferably sized such that when disposed within the interior of the main body  12  in the above-described manner, the opposed ends thereof do not protrude beyond respective ones of the opposed ends of the main body  12 . 
   As indicated above, in addition to the main body  12 , the scaffold plank  10  includes the end caps  14  which are attached to respective ones of the opposed ends of the main body  12 . As seen in  FIGS. 2 and 2A , each of the end caps  14  has a generally rectangular configuration, and includes an outer surface  38  which defines a pair of beveled or concave corner regions adjacent respective ones of the lateral sides thereof. In addition to the outer surface  38 , each end cap  14  has an inner surface  40  which includes an elongate channel  42  formed therein. The channel  42  is formed within each end cap  14  for purposes of reducing the overall weight thereof. As seen in  FIG. 2 , the channel  42  terminates inwardly of the lateral sides of the end cap  14 . 
   Formed on the inner surface  40  of each end cap  14  are a total of eight (8) rectangularly configured attachment tabs  44 . The attachment tabs  44  are arranged in two sets of four, with the attachment tabs  44  of each set being disposed in spaced relation to each other along a respective one of the longitudinal sides of the channel  42 . Additionally, the attachment tabs  44  of one set are disposed in opposed, linear alignment with respective ones of the attachment tabs  44  of the other set. Importantly, the attachment tabs  44  are oriented so as to be advanceable into respective ones of the cavities defined within the main body  12  and not interfere with any of the reinforcement webs  30  thereof. In this respect, the attachment tabs  44  are sized and configured such that when each opposed pair thereof is received into a respective one of the cavities of the main body  12 , those edges of the attachment tabs  44  disposed furthest from the channel  42  are in abutting contact with the inner surfaces of respective ones of the top and bottom walls  22 ,  26  of the main body  12 . Those of ordinary skill in the art will recognize that different numbers of attachment tabs  44  arranged in alternative patterns are contemplated in relation to the end caps  14 . In the scaffold plank  10 , each of the end caps  14  may be sonically welded to the main body  12 , or may alternatively be attached to the main body  12  through the use of fasteners such as pins, snap fit, or an adhesive. However, those of ordinary skill in the art will recognize that other methods may be employed to facilitate the attachment of the end caps  14  to the main body  12 . As is seen in  FIG. 1 , the end caps  14  are sized relative to the main body  12  such that when attached thereto, the longitudinal sides of the end caps  14  are substantially flush with the bottom surface  20  of the bottom wall  26  and top surface  24  of the top wall  22 , with the lateral sides of the end caps  14  being substantially flush with respective ones of the outer surfaces of the sidewalls  28 . 
   Both the main body  12  and end caps  14  of the scaffold plank  10  are preferably fabricated from a plastic material. A preferred plastic material is a ten percent to fifty percent glass-filled polypropylene/nylon blend. Such plastic material may alternatively comprise either virgin or recycled plastic. It is contemplated that the plastic or nylon material may be filled with either glass or another suitable reinforcement material to increase the structural integrity/rigidity thereof. Those of ordinary skill in the art will further recognize that the main body  12  and end caps  14  need not necessarily be fabricated from identical materials. In this respect, each of the end caps  14  could be fabricated from a metallic material such as aluminum. As indicated above, each of the reinforcement bars  36  is preferably fabricated from steel. 
   Additionally, the main body  12  of the scaffold plank  10  is preferably fabricated via an extrusion process. If one or more reinforcement bars  36  is to be included within the interior of the main body  12 , it is preferred that the plastic material used to form the main body  12  will be extruded about the reinforcement bar(s)  36 . However, those of ordinary skill in the art will recognize that the reinforcement bars  36  may be inserted into the interior of the main body  12  via a separate procedure which is conducted subsequent to the formation of the main body  12  via the extrusion process. The end caps  14  are preferably fabricated through the use of an injection molding or vacuum forming process and, as indicated above, secured to respective ones of the opposed ends of the main body  12  subsequent to the fabrication of the same. 
   Subsequent to the fabrication of the main body  12  via the extrusion process, it is contemplated that the nail holes  16  may be formed therein via a follow-up drilling operation. Additionally, the frame setting notches  18  may be formed in the bottom surface  20  via a follow-up grinding or machining operation. Moreover, the top surface  24  of the top wall  22  may be subjected to a grinding or machining operation for purposes of applying a texture or roughened feature thereto. Though not shown, it is further contemplated that the cavities defined by the main body  12  may be filled with structural foam or some equivalent thereto prior to the attachment of the end caps  14  to the main body  12  for purposes of increasing the structural strength or rigidity of the completed scaffold plank  10 . 
   Referring now to  FIGS. 3 and 4 , there is depicted a scaffold plank  100  constructed in accordance with a second embodiment of the present invention. The scaffold plank  100  also has an elongate, generally rectangular configuration and includes a main body having a top wall  104  which defines a top surface  106 , an opposed pair of longitudinally extending sidewalls  108  which are integrally connected to the top wall  104 , and an opposed pair of end walls  110  which are integrally connected to the top and sidewalls  104 ,  108  and define respective ones of the opposed ends of the scaffold plank  100 . Though the scaffold plank  100  of the second embodiment preferably does not include the previously described end caps  14  since the opposed ends thereof are defined by the end walls  100  of the main body  102 , those of ordinary skill in the art will recognize that such end caps  14  may be employed as an alternative to the integrally formed end walls  100 . Similar to the configuration of the outer surfaces  38  of the end caps  14 , the end walls  110  of the main body  102  may be formed to include beveled corner regions adjacent respective ones of the sidewalls  108 . 
   As is seen in  FIGS. 3 and 4 , the main body  102  of the scaffold plank  100  is formed to include four (4) channel members  112  which are integrally connected to the inner surface of the top wall  104  and extend longitudinally therealong in spaced, generally parallel relation to each other. The outermost pair of channel members  112  each have a generally L-shaped configuration and, in addition to being integrally connected to the inner surface of the top wall  104 , are integrally connected to the inner surfaces of respective ones of the sidewalls  108 . The central two channel members  112  each have a generally U-shaped configuration and are integrally connected to only the inner surface of the top wall  104 . In the scaffold plank  100 , the outermost pair of channel members  112  and inner surfaces of the top and sidewalls  104 ,  108  collectively define a pair of slots, with another pair of slots being collectively defined by the central two channel members  112  and inner surface of the top wall  104 . Each of these four (4) slots has a generally rectangular configuration and extends substantially along the length of the main body  102 . Additionally, each of these slots is sized and configured to accommodate a reinforcement bar  114  which is identically configured to the previously described reinforcement bar  36  and preferably fabricated from steel. 
   In addition to the channel members  112 , integrally connected to and extending perpendicularly from the inner surface of the top wall  104  are three (3) longitudinally extending primary reinforcement webs  116 . In the scaffold plank  100 , each of the primary reinforcement webs  116  is disposed equidistantly between an adjacent pair of channel members  112  and extends in generally parallel relation thereto. Integrally connected to and extending angularly between each of the primary reinforcement webs  116  and the channel members  112  of the corresponding pair are a plurality of secondary reinforcement webs  118  which are also integrally connected to the inner surface of the top wall  104  and extend generally perpendicularly relative thereto. As is best seen in  FIG. 4 , the channel members  112  and primary and secondary reinforcement webs  116 ,  118  are each sized and configured such that the distal surfaces thereof (i.e., those surfaces disposed furthest from the inner surface of the top wall  104 ) and are oriented inwardly from the distal edges of the sidewalls  108  and end walls  110  (or end caps  14 ) of the main body  102 . In this respect, the distal edges of the side and end walls  108 ,  110  of the main body  102  protrude slightly outwardly from the distal surfaces of the channel members  112  and primary and secondary reinforcement webs  116 ,  118  for reasons which will be described in more detail below. 
   In addition to the main body  102 , the scaffold plank  100  of the second embodiment may comprise a cover member  120  which also has an elongate, generally rectangular configuration and define opposed, generally planar surfaces. In the scaffold plank  100 , the cover member  120  is attached to the main body  102  such that the inner surface of the cover member  120  lies in abutting contact with the distal surfaces of the channel members  112  and primary and secondary reinforcements webs  116 ,  118 . In this respect, the length and width dimensions of the cover member  120  are slightly smaller than those of the main body  102  such that when the inner surface of the cover member  120  is placed in abutting contact with the channel members  112  and primary and secondary reinforcement webs  116 ,  118  in the aforementioned manner, the outer surface of the cover member  120  is substantially flush or continuous with distal edges of the side and end walls  108 ,  110  of the main body  102 . 
   The attachment of the cover member  120  to the main body  102  is preferably facilitated through the use of sonic welding, pins, or an adhesive. However, those of ordinary skill in the art will recognize that other methods may be employed to facilitate the attachment of the cover member  120  to the main body  102 . Since the cover member  120 , when attached to the main body  102 , does not protrude beyond the side and end walls  108 ,  110  of the main body  102 , the overall length, width and height dimensions of the scaffold plank  100  are governed by the main body  102  thereof. Though not shown, it is contemplated that a sealing strip will be compressed between the cover member  120  and the main body  102  when the cover member  120  is attached to the main body  102 . 
   In the second embodiment, the preferred height or thickness of the main body  102 , and hence the scaffold plank  100 , is in the range of from about 1.0 inch to about 2.50 inches, and preferably about 1.50 inches. The preferred width of the main body  102  is in the range of from about 6.0 inches to about 15.0 inches, and is preferably about 9.50 inches. The overall length of the main body  102  is variable, with it being contemplated that the same may be provided in lengths of either 6 feet, 9 feet, 12 feet, or 16 feet. 
   Like the main body  12  and end caps  14  of the scaffold plank  10  of the first embodiment, both the main body  102  and cover member  120  of the scaffold plank  100  of the second embodiment are preferably fabricated from a plastic material. As is the first embodiment, a preferred plastic material is a ten percent to fifty percent glass-filled polypropylene/nylon blend. An alternative plastic material may be either virgin or recycled plastic. It is contemplated that the plastic or nylon material may be filled with either glass or another suitable reinforcement material to increase the structural integrity/rigidity thereof. As indicated above, each of the reinforcement bars  114  is preferably fabricated from steel. However, the reinforcement bars  114  as well as the above-described reinforcement bars  36  may each be fabricated from a material other than steel. 
   In the scaffold plank  100  shown in  FIGS. 3 and 4 , four (4) reinforcement bars  114  are depicted as being disposed within respective ones of the four (4) slots extending within the interior of the main body  102 . Those of ordinary skill in the art will recognize that no reinforcement bars  114  need be provided within the main body  102 , and that less than four (4) reinforcement bars  114  may be included therein. The number of reinforcement bars  114 , if any, included in the interior of the main body  102  of the scaffold plank  100  is dependent upon the level of structural integrity or rigidity desired in relation thereto. Additionally, though the main body  102  is shown as including four (4) channel members  112  and three (3) primary reinforcement webs  116 , those of ordinary skill in the art will recognize that the main body  102  may be formed to include greater or fewer channel members  112  and/or primary reinforcement webs  116 . 
   As indicated above, no reinforcement bars  114  need to be provided within the main body  102 . In this respect, it is contemplated that as an alternative to the reinforcement bars  114  being included in the main body  102 , the channel members  112  may be formed to be of a solid cross-sectional configuration as opposed to partially defining the above-described rectangularly configured slots. In this respect, based upon the particular plastic material used to form the main body  102 , the formation of the same with the solid channel members  102  may be sufficient to impart the desired amount of structural integrity/rigidity to the scaffold plank  100 . 
   In the second embodiment, the main body  102  of the scaffold plank  100  is preferably fabricated via an injection molding process, as is the cover member  120  thereof. If one or more reinforcement bars  114  is to be included within the interior of the main body  102 , such reinforcement bar(s)  114  will typically be pre-positioned within the mold, with the plastic material thereafter being injection molded about the same, thus resulting in the reinforcement bars  114  being molded in place. Additionally, as seen in  FIG. 3 , it is contemplated that the mold may be formed to provide the top surface  106  of the top wall  104  with non-skid characteristics through the formation of multiple, generally circular protuberances  122  thereon, with such protuberances  122  being arranged in generally parallel rows. As an alternative to being formed to include the protuberances  122 , the top surface  106  of the top wall  104  may be subjected to a follow-up grinding or machining operation subsequent to the molding of the main body  102  for purposes of applying a texture or roughened feature thereto. The outer surface of the cover member  120  may also be formed to include a texture or roughened feature. Though the main body  102  and the cover member  120  are preferably fabricated via an injection molding process, it is contemplated that either or both of the main body  102  and cover member  120  may be fabricated via a vacuum forming or extrusion process. Additionally, though not shown, it is contemplated that the previously described nail holes  16  and/or frame setting notches  18  may be formed within the scaffold plank  100  via processes/techniques similar to those previously described in relation to the scaffold plank  10  of the first embodiment. 
   It is contemplated in the scaffold plank  100  of the second embodiment, the cover member  120  may be formed as an integral portion of the main body  102  as opposed to a separate component attached thereto. In this respect, the main body  102  including the cover member  120  as an integral portion thereof may be formed or fabricated as a totally symmetrical component or part. Both of the sides or faces of such symmetrical part could be provided with a texture or roughened feature, with the absence of any nail holes  16  and frame setting notches  18  allowing the same to be positioned upon scaffolding in any orientation. If formed to include the cover member  120  as an integral portion thereof, it is contemplated that the main body  102  will be molded in two identical halves defined by bisecting the side walls  108  along a common plane. These two symmetrical halves of the main body  102  (one of which would include the integrally formed cover member  120 ) would be attached to each other via sonic welding or an adhesive to facilitate the formation of the scaffold plank  100 . Each of the symmetrical halves could be individually fabricated via injection molding, rotational molding, or a vacuum forming process. 
   Referring now to  FIG. 5 , there is shown a scaffold plank  200  constructed in accordance with a third embodiment to the present invention. The scaffold plank  200  is preferably outfitted with a pair of end connectors  202  which are cooperatively engaged to respective ones of the opposed ends of the scaffold plank  200 . The structural and functional attributes of each end connector  202  (one of which is shown in  FIG. 5  as exploded from the scaffold plank  200 ) will be described in more detail below. 
   As seen in  FIG. 5 , the scaffold plank  200  is preferably a unitary structure which defines a generally planar, sheet-like top wall  204  and a generally planar, sheet-like bottom wall  206 . The top and bottom walls  204 ,  206  extend in spaced relation to each other along respective ones of a generally parallel pair of planes. Extending perpendicularly between corresponding pairs of the longitudinal edges of the top and bottom walls  204 ,  206  is a spaced, generally parallel pair of side walls  208 . Though the inner surfaces of the side walls  208  are generally planar, the outer surfaces thereof each include an integral upper rail  210  and an integral lower rail  212  extending longitudinally therealong in spaced, generally parallel relation to each other. The upper rails  210  extend along respective ones of the opposed longitudinal sides of the top wall  204 , and are each substantially flush with the outer surface of the top wall  204 . Similarly, the lower rails  212  extend along respective ones of the opposed longitudinal sides of the bottom wall  206  and are each substantially flush with the outer surface of the bottom wall  206 . As shown in  FIG. 5 , each of the upper and lower rails  210 ,  212  is preferably hollow, though the same may alternatively be formed to have solid cross-sectional configurations. Due to the inclusion of the upper and lower rails  210 ,  212  thereon, each side wall  208  defines an elongate slot  214 , the use of which will also be discussed in more detail below. 
   The scaffold plank  200  further comprises a plurality of reinforcement walls  216  which extend perpendicularly between the inner surfaces of the top and bottom walls  204 ,  206 . The reinforcement walls  216  extend longitudinally along the length of the scaffold plank  200  in spaced, generally parallel relation to each other. Though the reinforcement walls  216  are equidistantly spaced relative to each other, the spacing between the outermost pair of reinforcement walls  216  and respective ones of the side walls  208  is reduced in comparison to the spacing between the reinforcement walls  216 . As a result, an outer pair of cavities collectively defined by the top and bottom walls  204 ,  206 , outermost pair of reinforcement walls  216 , and side walls  208  each have a width which is less than that of multiple inner cavities which are each collectively defined by the top and bottom walls  204 ,  206  and an adjacent pair of the reinforcement walls  216 . As seen in  FIG. 5 , the scaffold plank  200  is formed to include five reinforcement walls  216 . As a result, the scaffold plank  200  includes four inner cavities and two outer cavities which, as indicated above, are of reduced width as compared to the inner cavities. However, those of ordinary skill in the art will recognize that the number of reinforcement walls  216  included in the scaffold plank  200  as shown in  FIG. 5  is exemplary only, in that greater or fewer reinforcement walls  216  may be formed to extend between the top and bottom walls  204 ,  206 . Also exemplary is the spacing between the reinforcement walls  216 , in that it is contemplated that the reinforcement walls  216  may be equidistantly spaced relative to each other and to the side walls  208 , thus causing all of the cavities defined by the scaffold plank  200  to be of equal size. 
   It is contemplated that the scaffold plank  200  of the third embodiment will be fabricated in its entirety from a non-metal material via an extrusion or injection molding process. Exemplary materials for the scaffold plank  200  include various types of plastics (e.g., glass-filled polyethylene), fiber reinforced composites, or combinations thereof. In this regard, it is further contemplated that the extrusion process preferably used to facilitate the formation of the scaffold plank  200  may be carried out in a manner wherein various portions of the scaffold plank  200  are fabricated from a fiber reinforced plastic or composite, with other portions simply being fabricated from a non-reinforced plastic material. More particularly, depending on the level of structural integrity desired for the scaffold plank  200 , one or more of the reinforcement walls  216  may be fabricated from a fiber reinforced composite material, with the remainder of the scaffold plank  200  being fabricated from a plastic material. As indicated above, the extrusion process preferably used to facilitate the formation of the scaffold plank  200  may be completed such that the scaffold plank  200  is a unitary structure, despite proscribed areas of the scaffold plank  200  being fabricated from differing non-metallic materials. As a further variation, the scaffold plank  200  as shown in  FIG. 5  may be fabricated entirely from a non-reinforced plastic material, with reinforcing sheets of a fiber reinforced composite material being applied to the outer surface of the top wall  204  and/or the outer surface of the bottom wall  206  for purposes of increasing the structural integrity/rigidity of the scaffold plank  200 . In the scaffold plank  200 , the outer surface of the top wall  204  and the outer surface of the bottom wall  206  are preferably formed to have a roughened or textured feature to provide the scaffold plank  200  with non-slip characteristics. However, those of ordinary skill in the art will recognize that the non-skid, roughened texture may be included on only the outer surface of the top wall  204 . 
   Referring now to  FIGS. 5-7 , as indicated above, the scaffold plank  200  of the third embodiment preferably includes a pair of end connectors  202  cooperatively engaged to respective ones of each of the opposed ends thereof. Each end connector  202  includes an engagement portion  218  having a main body  220  which defines an arcuate, generally concave body surface  222 . The body surface  222  spans approximately ninety degrees. Formed within the main body  220  is a spaced pair of notches  224 , each of which has a generally V-shaped configuration defining an arcuate lower apex. In addition to the main body  220 , the engagement portion  218  of the end connector  202  includes a spaced, identically configured pair of arms  226  which are integrally connected to the main body  220 . Each of the arms  226  defines an arcuate, generally concave arm surface  228  which, like the body surface  222 , also spans approximately ninety degrees. The main body  220  and arms  226  are oriented relative to each other such that one of the notches  224  is disposed between the arms  226 , with the remaining notch  224  being disposed between one arm  226  and one lateral end of the main body  220 . Importantly, the main body  220  and arms  226  are oriented relative to each other such that the arms surfaces  228  of the arms  226  are continuous with the body surface  222  of the main body  220 . Thus, the arms surfaces  228  and portions of the body surface  222  collectively define engagement surfaces which span, in total, approximately 180°. Each arm  226  also has a generally V-shaped configuration when viewed from a top perspective, with the side walls of the arm  26  oriented between the notches  224  being continuous with the side walls of such notches  224 . One side wall of the remaining arm  226  is continuous with the side wall of the notch  224  disposed between the arms  226 . As seen in  FIG. 5 , due to the shape of the engagement portion  218  of the end connector  202 , the depth of the notch  224  located between the arms  226  appears to be greater than that of the remaining notch  224  due to the side wall of the notch  224  between the arms  226  being continuous with one side wall of each of the arms  226 . 
   In addition to the engagement portion  218 , the end connector  202  includes a plurality of elongate attachment fingers  230  which protrude perpendicularly from the side of the main body  220  opposite that including the body surface  222  formed therein. The fingers  230  extend in spaced, generally parallel relation to each other, and are each preferably hollow. As is best seen in  FIG. 5 , the fingers  230  are sized and configured to be advanceable into respective ones of the cavities defined by the scaffold plank  200 . In this regard, since the cavities of the scaffold plank  200  are of differing widths as indicated above, the outermost pair of fingers  230  of the end connector  202  are of reduced width as compared to the remaining fingers  230 . In this regard, the outermost pair of fingers  230  are sized and configured to be advanceable into respective ones of the outer pair of cavities defined by the scaffold plank  200 , with the remaining fingers  230  being sized and configured to be advanceable into respective ones of the inner cavities defined by the scaffold plank  200 . The advancement of the fingers  230  into respective ones of the cavities is limited by the abutment of a peripheral portion of the surface of the main body  220  from which the fingers  230  extend against corresponding lateral edges of the top and bottom walls  204 ,  206  and side walls  208  of the scaffold plank  200 , in the manner shown in  FIG. 6 . 
   It s contemplated that the end connector  202  will be fabricated from a plastic material via an injection molding process, with the attachment fingers  230  being integrally connected to the main body  220  of the engagement portion  218 . As seen in  FIGS. 6 and 7 , it is further contemplated that the structural integrity of each end connector  202  may optionally be increased through the inclusion of a reinforcement plate  244  therein. The reinforcement  244  is preferably fabricated from a metal material (e.g., steel), and has a shape which is complimentary to that of the main body  220 , arms  226 , and fingers  230 . More particularly, the reinforcement plate  244  includes a plurality of reinforcement fingers  246  which are sized and configured to be advanceable into the interiors of respective ones of the attachment fingers  230 . Additionally, the reinforcement plate  244  includes a pair of arcuate reinforcement arms  248  which are extensible into the interiors of respective ones of the arms  226 . Since the end connector  202  is preferably fabricated via an injection molding process, it is contemplated that the reinforcement plate  244  will initially be included in the mold cavity, with the plastic material used to form the remainder of the end connector  202  being injected into the mold cavity in a manner effectively encapsulating the reinforcement plate  244  in the manner shown in  FIG. 6 . 
   As indicated above, the cooperative engagement of each end connector  202  to a respective end of the scaffold plank  200  is facilitated by the advancement of the fingers  230  of the end connector  202  into respective ones of the elongate cavities defined by the scaffold plank  200 , such advancement terminating when the end of the scaffold plank  200  is abutted against the main body  220  of the engagement portion  218  in the above-described manner. It is contemplated that each end connector  202  will be maintained in firm engagement to the scaffold plank  200  through the use of multiple fasteners such as screws  250 . As seen in  FIGS. 5 and 6 , one pair of screws  250  is advanced through respective ones of a pair of openings disposed within one side wall  208  of the scaffold plank  200  and into respective ones of a complimentary pair of internally threaded apertures  252  disposed within one of the outer pair of fingers  230  of the end connector  202 . A second pair of screws  250  is extended through openings in the remaining side wall  208  and into a complimentary pair of internally threaded apertures  252  disposed in the remaining finger  230  of the outer pair. Since the openings in the side walls  208  of the scaffold plank  200  are disposed within the bottom surfaces of respective ones of the slots  214 , the heads of the screws  250  do not protrude beyond the outermost surfaces of the upper and lower rails  210 ,  212  of each side wall  208 , i.e., the heads of the screws  250  are effectively contained within respective ones of the slots  214 . It is contemplated that the mechanical interlock between the end connectors  202  and scaffold plank  200  facilitated by the screws  250  may be supplemented by the application of an adhesive to prescribed portions of each end connector  202  prior to the advancement of the attachment fingers  230  thereof into the interior of the scaffold plank  200 . Additionally, the screws  250  may be omitted in their entirety as a result of the use of an adhesive. 
     FIGS. 8 and 9  depict the manner in which a pair of scaffold planks  200  which each include the end connectors  202  attached to each of the opposed ends thereof are interfaced to a horizontal support bar  254  of a scaffolding support frame  256 . As seen in  FIGS. 6 ,  8  and  9 , the end connector  202  is engaged to the support bar  254  such that the arms  226  extend about the support bar  254 . More particularly, the outer surface of the support bar  254  is abutted directly against the arcuate body surface  222  of the main body  220  and against the arms surfaces  228  of the arms  226 . Advantageously, since the body surface  222  spans the entire length of the main body  220 , the scaffold plank  200  is not susceptible to rocking or tipping when weight or downward force is applied to the longitudinal edges thereof. 
   Once one end connector  202  of one scaffold plank  200  is cooperatively engaged to the support bar  254  in the above-described manner, one end connector  202  of the remaining scaffold plank  200  is itself cooperatively engaged to the same support bar  254 . In this regard, the arms  226  of the end connector  202  of one scaffold plank  200  are nested into respective ones of the notches  224  of the corresponding end connector  202  of the other scaffold plank  200  in the manner shown in  FIG. 9 . When the corresponding end connectors  202  of the scaffold planks  200  are interfaced to the common support bar  254  as shown in  FIG. 9 , the contours of the top surfaces of the arms  226  results in the distal portions thereof being recessed downwardly relative to the top surfaces of the main bodies  220  of the engagement portions  218  of the corresponding end connectors  202 . 
   As seen in  FIG. 6 , further in accordance with the present invention, it is contemplated that each end connector  202  of each scaffold plank  200  may optionally be provided with a locking clip  258  which is preferably fabricated from a resilient metallic material (e.g., steel) and secured to the main body  220  of the engagement portion  218  via one or more fasteners such as screws  260 . It will be recognized that each end connector  202  may be outfitted with one relatively large locking clip  258 , or multiple, smaller identically configured locking clips  258  disposed in spaced relation to each other. The locking clip  258  is sized and configured to frictionally engage the support bar  254  in the manner shown in  FIG. 6 , thus inhibiting the easy uplift of the end connector  202  out of engagement to the support bar  254 . Those of ordinary skill in the art will recognize that the inclusion of the locking clip(s)  258  are optional, and that alternative locking mechanisms may be included in each end connector  202  to facilitate the secure connection thereof to the scaffolding support frame  256 . 
   Referring now to  FIG. 10 , further in accordance with the present invention, it is contemplated that the slots  214  included in the side walls  208  of each scaffold plank  200  may be used to accommodate edge connectors (not shown) which effectively maintain two or more scaffold planks  200  in side-by-side attachment to each other, i.e., the longitudinal side wall  208  of one scaffold plank  200  is cooperatively engaged to a corresponding side wall  200  of an adjacent scaffold plank  200 . In  FIG. 10 , three scaffold planks  200  are shown in such side-by-side engagement, with the end connectors  202  of each set of three interconnected scaffold planks  200  themselves being cooperatively engaged to a common horizontal support bar  254  of the scaffolding support frame  256 . As further shown in  FIG. 10 , it is also contemplated that a corner connector  260  may be used in conjunction with two interconnected sets of scaffold planks  200 , the corner connector  260  being sized and configured to allow the interconnected sets of scaffold planks  200  to be effectively joined to each other, despite being disposed at a prescribed angular displacement relative to each other. As shown in  FIG. 10 , the corner connector  260  includes an opposed pair of side edges, each of which is formed to include an arcuate, generally concave engagement surface  262 , a plurality of arms  264 , and a plurality of notches  266 . The engagement surface  262 , arms  264  and notches  266  of each side edge are structurally and functionally identical to the body surface  222 , notches  224 , and arms  226  of each end connector  202 . In this regard, when the end connectors  202  of the interconnected scaffold planks  200  of one set are cooperatively engaged to the common support bar  254 , one side edge of the corner connector  260  may be cooperatively engaged to the same support bar  254 , with the arms  264  of the corner connector  260  being nested within respective ones of the notches  224  of the interconnected scaffold planks  200 , and the arms  226  of the interconnected scaffold planks  200  being nested within respective ones of the notches  266  of the corner connector  260 . 
   The corner connector  260  is preferably fabricated from a plastic material via an injection molding process, with the top surface of the corner connector  260  also being provided with a roughened, non-slip texture. As seen in  FIG. 10 , the corner connector  260  is sized to span approximately 30°, though those of ordinary skill in the art will recognize that the corner connector  260  may be formed to span differing angular intervals. Additionally, multiple corner connectors  260  may be cooperatively engaged to the scaffolding support frame  256  proximate to each other so as to collectively define a span of more than 30°. For example, two corner connectors  260  as shown in  FIG. 10  disposed in side-by-side relation to each other would span approximately 60°, with three corner connectors  260  interlocked to the scaffolding support frame  256  in side-by-side relation to each other spanning approximately 90°. Though the corner connector  260  shown in  FIG. 10  is shown as being sized to be interfaced to two sets of three interconnected scaffold planks  200 , the corner connector  260  may alternatively be sized and configured to span between only two interconnected scaffold planks  200 , or even individual scaffold planks  200  which are angularly displaced relative to each other. 
   Additional modifications and improvements of the present invention may also be apparent to those of ordinary skill in the art. In this respect, the planks formed in accordance with the present invention may be used in applications other than for scaffolding. Thus, the particular combination of parts described and illustrated herein is intended to represent only certain embodiments of the present invention, and is not intended to serve as limitations of alternative devices within the spirit and scope of the invention