Patent Publication Number: US-6983824-B1

Title: Portable structural system

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Patent Application No. 60/370,931 filed Apr. 9, 2002. 

   FIELD OF THE INVENTION 
   This invention relates to a portable structural system for supporting horizontal work surfaces such as scaffold planks, workbenches and shelves which includes braces that mount to upright lengths of standard construction materials such as steel pipes or 2×4 studs. 
   BACKGROUND OF THE INVENTION 
   The installation of scaffolds or workbenches at a construction site may require extensive, specialized structural components that must be taken to a job site, assembled for use and then disassembled and removed after use. Moreover, there is often a need for a standard brace for supporting work benches or shelves that can securely mount to the upright studs of a frame. What is needed a system that includes portable, standardized, reusable braces and fittings that can mount to commonly available construction materials such as upright 2×4 studs to provide the supporting structure for a scaffold, a shelf or a workbench. What is also needed is such a structural system that can be assembled and disassembled very rapidly. 
   SUMMARY OF THE INVENTION 
   Accordingly, it is object of the present invention is to provide a portable structural system that employs reusable, portable braces and fittings that can be mounted to commonly available construction materials. It is another object of this invention to provide reusable braces having fittings that mount to upright lengths of construction material such as the studs of wood frame structures. It is yet another object of the present invention to provide compact, reusable braces and fittings for supporting scaffold planks or other work surfaces such as workbenches. It is still yet another object of the present invention to provide a portable structural system that can be assembled and disassembled very rapidly. 
   These and other objects of the invention are attained in an improved, portable scaffolding system which employs braces that are particularly adapted, at their inboard ends, to mount to standard 2×4 studs. Each brace has spaced upper and lower inboard fittings fixed to their inboard end which are aligned and configured for receiving and securing to vertical lengths of 2×4 studs such as the type of 2×4 studs that are typically used to frame wood structures. A horizontal support projects from the upper inboard fitting and a diagonal support joins the horizontal support and the lower outboard fitting. When the braces are mounted to uprights 2×4 studs, the horizontal supports of the braces provide support for a working surface such as a panel for a workbench, planks for shelves or planks for scaffolding. The panel or planks can also be clamped to the horizontal supports of the braces to further stabilize the structure. To provide additional support, an outboard fitting can be added to the brace opposite the upper inboard fitting. The outboard fitting can be configured to clamp to a stud or a vertical length of standard pipe to provide an outboard support for each brace. Base fittings can also be provided for securing the lower ends of the outboard supports to a floor. 
   As can be seen from the forgoing description, the portable structural system includes components that can be used with readily available lengths of construction material to erect a complete structure. Because the majority of the structure is comprised of standard, available materials such as standard pipe or 2×4 studs, the braces and other supporting hardware can be easily transported to a work site and can be assembled and disassembled very rapidly. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention and its many attendant objects and advantages will become better understood upon reading the following detailed description of the preferred embodiment in conjunction with the following drawings, wherein: 
       FIG. 1  is a perspective view of the invention scaffolding system shown in relation to a wood frame structure. 
       FIG. 2  is a perspective view of a brace assembly of the invention scaffolding system. 
       FIG. 3  is a view taken from plane  3 — 3  of  FIG. 2  showing a rail fitting. 
       FIG. 4  is a view taken from plane  4 — 4  of  FIG. 2  showing a base fitting. 
       FIG. 5  is a view taken from plane  5 — 5  of  FIG. 2  showing a brace. 
       FIG. 5A  is a top view of the brace shown in  FIG. 5 . 
       FIG. 6  is a view taken from plane  6 — 6  of  FIG. 5  showing a lower inboard fitting. 
       FIG. 6A  is a top view of the lower inboard fitting shown in  FIG. 6 . 
       FIG. 7  is a side view of an alternate brace. 
       FIG. 7A  is a side view of an alternate upper fitting for the brace of  FIG. 7 . 
       FIG. 7B  is a side view of an alternate lower fitting for the brace of  FIG. 7 . 
       FIG. 8  is a view taken from plane  8 — 8  of  FIG. 7 . 
       FIG. 8A  is a top view of the lower inboard fitting shown in  FIG. 8 . 
       FIG. 9  is a view taken from plane  9 — 9  of  FIG. 7A . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Turning now to the drawings, wherein like reference numerals identify identical or corresponding elements, and more particularly to  FIG. 1  thereof, a portable structure  10  is shown in relation to frame structure  5  which includes upright 2×4 studs  5 A and  5 B. Portable structure  10  should be understood to encompass a scaffold structure for supporting workers, a structure for supporting a horizontal panel to provide a workbench or even structure for supporting a storage shelf or series of storage shelves. Portable structure  10  includes left and right brace assemblies  12  which are substantially identical. As shown in  FIG. 1 , brace assemblies  12  each include a brace  20 , and an outboard support member  140 . It should be understood that outboard support member  140  can be replaced by an upright wooden stud such as a standard 2×4. In  FIG. 1 , brace  20  is shown supporting two scaffold planks  120 A and  120 B. Outboard support member  140  as shown in  FIG. 1  is a length of standard pipe. Outboard member  140  stands upon a base fitting  142  and it carries a lower rail fitting  152  and an upper rail fitting  162  which receive and support rails  172  and  182  respectively. 
   Brace assembly  12  is shown in greater detail in  FIG. 2 . Brace assembly  12  includes a brace  20  which engages stud  5 A with an upper inboard fitting  22  and a lower inboard fitting  52 . A horizontal member  56  projects generally horizontally from upper inboard fitting  22 . An outboard fitting  60  is fixed to the end of horizontal member  56  opposite upper inboard fitting  22 . A diagonal member  64  rigidly connects horizontal member  56  and lower inboard fitting  52 . A strut  68  reinforces brace  20  by rigidly connecting horizontal member  56  and diagonal member  64 . 
   As can be seen in  FIG. 2 , outboard fitting  60  of brace  20  clamps to outboard member  140  by means of a T-bolt  60 A. T-bolt  60 A has a threaded shaft that is received by a threaded insert  60 B which is welded to outboard fitting  60 . The wall of outboard fitting includes a hole (not shown) so that T-bolt  60 A can be engage the surface of outboard member  140  and be turned to apply a clamping force against outboard member  140 . It should be understood that outboard member  140  can be another type of material such as a 2×4 stud if outboard fitting  60  of brace  20  is adapted to receive another type of material. 
     FIG. 3 , which is taken from plane  3 — 3  of FIG.  2 ., illustrates lower rail fitting  152  in greater detail. Rail fitting  152  mounts lower rail  172  to outboard member  140 . It is to be understood that upper rail fitting  162  has the same configuration as lower rail fitting  152  and performs the same function for upper rail  182 . As can be seen in  FIG. 3 , lower rail fitting  152  includes a first portion  154  for receiving and clamping to outboard member  140  and a second portion  156  for receiving and clamping to lower rail  172 . As with outboard fitting  60 , first portion  154  of lower rail fitting  152  includes a T-bolt  154 A and a threaded insert  154 B as well as a hole  154 C for receiving T-bolt  154 A. Second portion  156  of lower rail fitting also includes a T-bolt  156 A, a threaded insert  156 B and a hole  156 C for receiving T-bolt  156 A. When T-bolt  154 A and T-bolt  156 A are turned tightly against outboard member  140  and lower rail  172  respectively, lower rail  172  is firmly mounted to outboard member  140 . 
     FIG. 4  is taken from plane  4 — 4  of  FIG. 2 .  FIG. 4  illustrates base fitting  142  in greater detail. Base fitting  142  provides a base for outboard member  140 . As can be seen in  FIG. 4 , base fitting  142  includes a flat base flange  144  for resting upon a flat surface and cylindrical body  146  for receiving outboard member  140 . Flange  144  includes fastener holes  144 A for optionally receiving fasteners (not shown) for fastening base fitting  142  to a floor such as floor  7  shown in  FIG. 1 . Fixed to cylindrical body  146  is a threaded insert  146 A which aligns with a hole in the wall of cylindrical body  146  (not shown). The threaded insert receives a T-bolt  146 B. When T-bolt  146 B is tightened against outboard member  140 , outboard member  140  is provided with a securely mounted base. 
     FIG. 5  is taken from plane  5 — 5  of  FIG. 2  and  FIG. 5A  is a top view of brace  20 . Brace  20  is an important component of this structural system. A spaced pair of braces such as brace  20  can be used to support a workbench or a shelf. A simple but very sturdy workbench can be constructed using a spaced pair of braces such as brace  20  where the braces are supported by outboard members and where the work surface is strong, rigid panel of material that is firmly clamped to both braces. 
   Brace  20  is designed to mount to an upright stud and provide a horizontal support for a working surface such as a shelf, workbench surface or scaffold planks. Brace  20  may be mounted to a free standing stud, as long as that free standing stud is otherwise supported. Brace  20  is primarily designed to provide a brace that securely mounts to a frame structure such as might be found in an unfinished interior building space or an unfinished garage. Brace  20  can even be used with a frame structure when dry wall is covering that frame structure if a small portion of that dry wall is removed. 
   Upper and lower inboard fittings  22  and  52  are designed to clamp to an upright stud. Upper and lower inboard fittings  22  and  52  are shaped and aligned to be compatible with the geometry of a stud. Upper and lower inboard fittings  22  and  52  can also be fastened to a stud with the installation of fasteners such a wood screws for additional support. It is to be understood that upper inboard fitting  22  of brace  20  has the same basic configuration as lower inboard fitting  52  and performs the same basic function of clamping to stud  5 A in the same basic way as lower inboard fitting  52 . 
   Lower inboard fitting  52  is particularly designed to grip a 2×4 stud.  FIG. 6 , which is taken from plane  6 — 6  of  FIG. 5 , provides a detailed view of lower inboard fitting  52 .  FIG. 6A  is a top view of lower inboard fitting  52 . Lower inboard fitting  52  includes a channel shaped body  52 A which is welded to the lower end of diagonal member  64 . Channel shaped body  52 A has first and second parallel flanges  53  and  54  which are spaced to accommodate the width of a structural stud. Formed into the corners of first flange  53  are two inwardly projecting cleats  53 A and  53 B. A threaded insert  54 A is fixed to second flange  54 . Threaded insert  54 A aligns with a hole  54 B in second flange  54 . Threaded insert  54 A receives a correspondingly threaded T-Bolt  54 C. When T-Bolt  54 C is tightened against a stud, cleats  53 A and  53 B are forced against the surface of the stud, penetrate the surface of the stud so that lower inboard fitting  52  grips the stud. Lower inboard fitting  52  also has a fastener hole  55 A so that wood screw can be installed in order to more securely attach lower inboard fitting  52  to a stud. Brace  20  and the other fittings described above are preferably made from at least medium grade steel having a material thickness sufficient to carry significant loads and function without deforming plastically. As noted above, brace  20  and the fittings described above can be repeated in various combinations to construct shelves, workbenches and scaffolding. Because available materials are used to construct these structures, limited amounts of the specialized hardware described above are needed to construct an extensive structure. Because simple T-Bolt clamps are used repetitively in brace  20  and the other fittings described above, a entire structure can be assembled very rapidly. Structures constructed using the portable structural system can have a wide range of load carrying capacities depending on the number and spacing of braces and the degree to which braces are fastened to frame studs and the degree to which planking is clamped to the braces. These things can be accomplished with the repetitious use of the fittings and braces described above. 
     FIG. 7  shows an alternate brace  320  of the invention structural system. Alternate brace  320  includes interchangeable inboard fittings which can be mounted to standard interfaces presented by the horizontal and diagonal members of brace  320 . The interchangeable inboard fittings of brace  320  are designed to accommodate either vertical studs or a flat wall surface backed by vertical studs.  FIG. 7  shows alternate brace as disassembled. However, alternate brace  320  should be completely assembled using one of the two sets of inboard fittings shown, as appropriate, before alternate brace  320  is mounted to a frame structure or a wall. 
   Brace  320  is fashioned from steel tube having a square cross section. Brace  320  includes a horizontal member  356 , a strut  368  and a diagonal member  364 . Upper and lower inboard fittings  322  and  352  shown in  FIG. 7  or upper and lower inboard fittings  322 A and  352 A shown in  FIGS. 7A and 7B  can be interchangeably fixed to brace  320 . Upper inboard fitting  322  includes a horizontal connecting member  356 A which mates to horizontal member  356 . Lower inboard fitting  322  includes a diagonal connecting member  364 A which mates to diagonal member  364 . Corresponding fastener holes  402 ,  404 ,  402 A and  404 A in horizontal connecting member  356 A and horizontal member  356  receive fasteners  502  as shown in  FIG. 9 . A similar arrangement including fastener holes  470 A,  470 B,  470 C and  470 D in diagonal connecting member  364 A and diagonal member  364  also receive fasteners substantially as shown in  FIG. 9 . 
   As can be seen in  FIGS. 8 and 8A , upper and lower inboard fittings  322  and  352  are substantially identical to upper and lower inboard fittings  22  and  52  of brace  20  shown in  FIGS. 6 and 6A . Lower inboard fitting  352  shown in  FIGS. 8 and 8A  includes a channel shaped body  352 A which is welded to the inboard lower end of diagonal connecting member  364 . Channel shaped body  352 A has first and second parallel flanges  353  and  354  which are spaced to accommodate the width of a structural stud. Formed into the corners of first flange  353  are two inwardly projecting cleats  353 A and  353 B. A threaded insert  354 A is fixed to second flange  354 . Threaded insert  354 A aligns with a hole  354 B in second flange  354 . Threaded insert  354 A receives a correspondingly threaded T-Bolt  354 C. When T-Bolt  354 C is tightened against a stud, cleats  353 A and  353 B are forced against the surface of the stud, penetrate the surface of the stud so that lower inboard fitting  352  grips the stud. Lower inboard fitting  352  also has a fastener hole  355 A so that wood screw can be installed in order to more securely attach lower inboard fitting  352  to a stud. 
   As can be seen in  FIGS. 7A ,  7 B and  9 , alternate upper and lower inboard fittings  322 A and  352 A do not have channel shaped bodies but have mounting plates  422 A and  452 A which are welded to the inboard ends of alternate horizontal connecting member  356 B and alternate diagonal connecting member  364 B respectively. Alternate horizontal connecting member  356 B of alternate upper inboard fitting  322 A includes a pair of fastener holes  460 E and  460 F which match fastener holes  460 A and  460 B of horizontal member  356 . In the same way, alternate diagonal connecting member  364 B includes a pair of fastener holes  470 E and  470 F which match fastener holes  470 A and  470 B of diagonal member  364 . Fasteners such as fastener  502  shown in  FIG. 9  are used to fasten alternate upper and lower inboard fittings  322 A and  352 A to brace  320 . Alternate upper and lower inboard fittings  322 A and  352 A each have a mounting plate such as mounting plate  422 A shown in  FIG. 9 . Mounting plate  422 A has a pattern of fastener holes  460 A,  460 B,  460 C and  460 D which receive fasteners such as wood screws which are used to fasten brace  320  to the vertical studs behind the wall board or the sheet rock of a wall. 
   As can be understood from the above description, brace  320  may be mounted either to a frame including vertical studs using fittings  322  and  352  or to a flat wall including a frame covered by wall board or dry wall using alternate fittings  322 A and  352 A. With this arrangement, a workman can quickly select and assemble interchangeable components such that braces can be mounted either to flat surfaces or a framework that include vertical studs. 
   Brace  20  and brace  320  and the other fittings described above are preferably made from at least medium grade steel having a material thickness sufficient to carry significant loads and function without deforming plastically. As noted above, brace  20 , brace  320  and the fittings described above can be repeated in various combinations to construct shelves, workbenches and scaffolding. Because available materials are used to construct these structures, limited amounts of the specialized hardware described above are needed to construct an extensive structure. Because simple T-Bolt clamps and other standard fasteners are used repetitively in brace  20  and brace  320  and the other fittings described above, a entire structure can be assembled very rapidly. Structures constructed using the portable structural system can have a wide range of load carrying capacities depending on the number and spacing of braces and the way in which braces are fastened to frame studs and the way in which working surfaces are clamped to the braces. Accordingly, a multitude of configurations can be constructed by using the fittings and braces described above. 
   Accordingly, the portable structural system described above meets an objective of the invention by providing a portable structural system that employs reusable, portable braces and fittings that can be mounted to commonly available construction materials. The portable structural system described above meets an another object of this invention by providing compact braces that can be quickly mounted to wooden studs in frame structures. The portable structural system described above meets yet another object of the present invention by providing braces and fittings that can be used with a very high degree of versatility to construct scaffolding systems, shelves, shelving systems and workbenches. 
   Numerous modifications and variations of this preferred embodiment may occur to those skilled in the art in light of this disclosure. Accordingly, it is expressly to be understood that these modifications and variations, and equivalents thereof, shall be considered to be within the spirit and scope of the invention as defined in following claims, wherein