Patent Publication Number: US-2006010621-A1

Title: Hybrid modular ramp

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      Not Applicable  
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
      Not Applicable  
     REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX  
      Not Applicable  
     BACKGROUND OF THE INVENTION  
      The Hybrid Modular Ramp is related to the field of temporary or movable residential wheelchair no step accessability to homes.  
     BRIEF SUMMARY OF THE INVENTION  
      The general idea of this invention is a sectional or modular galvanized steel unit with components of each section or module having the ability to be interchange or connected with/to other components or modules of the same. The use of other materials such as lumber are integrated into each module or section as the flooring. There are 2 basic styles of these modules. First is the inclined module which is rigidly welded at a slope or pitch of 1:12, second is the flat module which is rigidly welded at no slope or pitch (level). The rigid welding of each style of module prevents the problem of installing each module other than as intended or specified. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       FIG. 1 , Hybrid Modular Ramp System Exploded View. This drawing view shows the assembly or disassembly process of each module and several modules together. The indication of fastener orientation is depicted by dashed lines. The sides of each module are indicated by “ramp railing”, the floor of each module is indicated by “ramp base” and the connections are indicated as “connect leg to railing section using (4) #14×2″ self-tapping screw bolt”, “connect railing section to railing section using 3½″× 5/16″ bolts” and “connect ramp base section to ramp base section using 2½″× 5/16″ bolts” accordingly.  
       FIG. 2 , Hybrid Modular Ramp System Plan View. This drawing is a top view of a flat module section connected to an incline module section and a flat module extension. The dashed lines indicate the wood flooring that can be used as the floor material for each module. All dimensions are listed accordingly and fastener notations are present on the drawing.  
       FIG. 3 , Hybrid Modular Ramp System Elevation View. This drawing is a side view of a flat module that is connected to an incline module. All dimensions are listed accordingly and fastener notations are present on the drawing.  
       FIG. 4 , Hybrid Modular Ramp System Section View. This drawing is a cross sectional view of either a flat or incline section. There is a blow up of the welding connections indicated and noted on this drawing. The inclusion of leg bracing is also depicted on this drawing. All dimensions are listed accordingly and fastener notations are present on the drawing. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      The Hybrid Modular Ramp is a modular residential wheelchair home accessible no step system that allows many different configurations. There are 2 types of modules, the incline module and the flat module.  
      Incline Module Description. This module has an assembled size as a 3 dimensional parallelogram (length=60″, height=36″, width=40″, pitch=0″ at grade and 5″ at the 60″ length and all vertical structures are perpendicular to level grade. This is a slope of 1 in 12). The incline module has only one configuration, as an incline ramp section consisting of a left and right side rails and a base.  
      Incline Module Assembly. This is assembled using a left and right incline module side rails and an module base. The left and right side rails are attached to opposite sides of the base using four 2½″× 5/16″ bolts, eight 5/16″ flat washers and four 5/16″ locking nuts (or equivalent fasteners) inserted through the 4 holes on each side of the respective rail bottoms and base sides. The side rails shall mirror each other on either side of the base. The base shall be placed with surface of single plane facing up. The sides shall be mounted to the base with the vertical spindles facing out. 1″ square plastic end caps (or equivalent caps) are inserted into each of the 4 open ends of the side rail top tubes. This incline module is now ready for installation to the Hybrid Modular Ramp System as an incline ramp section.  
      Flat Module Description. This module has an assembled size as a 3 dimensional rectangular cube (length=60″, height=36″, width=40″, pitch=0″) when assembled with 2 flat side rails and a base. The flat module has 4 basic configurations, all of which are as flat ramp sections. The configurations vary according to the types of components assembled to each base. There are 4 different components that are used in the flat module configurations (1. Flat side rail 2. End rail 3. Base 4. Base extension).  
      Flat Module Assembly. This is assembled using a module base and various combinations of flat side rail/s, end rail/s and base extension/s The flat side rails are universal from left to right and are attached to opposite sides of the base using four 2½″× 5/16″ bolts, eight 5/16″ flat washers and four 5/16″ locking nuts (or equivalent fasteners) inserted through the 4 holes on each side of the respective rail bottoms and base sides. The side rails shall mirror each other on either side of the base. The base shall be placed with surface of single plane facing up. The sides shall be mounted to the base with the vertical spindles facing out. 1″ square plastic end caps (or equivalent caps) are inserted into each of the 4 open ends of the side rail top tubes. Flat rail/s may be left off of 1 or both sides if attaching a base extension/s.  
      Base Extension Attachment. Attaching a base extension to a base using four 2½″× 5/16″ bolts, eight 5/16″ flat washers and four 5/16″ locking nuts (or equivalent fasteners) inserted through the 4 holes on each side of the respective base and base extension. It is recommended to leave out the 2 far end fasteners until after installation as a flat section is completed (this makes support installation easier). The base and base extension shall be placed with surface of single plane facing up and against each other on their respective longest sides. The base extension is universal from left to right applications. This flat module is now ready for installation to the Hybrid Modular Ramp System as a flat ramp section.  
      End Rail Attachment. End rail/s are attached to opposite end/s of the base using three 3½″× 5/16″ bolts, six 5/16″ flat washers and three 5/16″ locking nuts (or equivalent fasteners) inserted through the 2 holes on each side of the respective end rail bottom/s and base and through the top hole/s of the adjacent side rail/s spindle and end rail spindle top hole. End rails are universal from end to end. If a flat module has only 1 or no side rails then the upper spindle hole of the end rail is to be fastened to the joiner bar with one 2½″× 5/16″ bolt, two 5′16″ washers and one 5/16″ locking nut (or equivalent fastener). The end rails shall mirror each other on either end of the base. The base shall be placed with surface of single plane facing up. The end rail/s shall be mounted to the base with the vertical spindles facing in. 1″ square plastic end caps (or equivalent caps) are inserted into each of the 4 open ends of the end rail/s top tubes. When end rails are to be used they are to be installed after the module installation to the Hybrid Modular Ramp System as a flat ramp section. The space taken up by the support leg is required for proper fitment to the flat ramp section. The end rail attachment is completed by installing two #14×2″ self-tapping bolts through the 2 available lowest holes on each spindle of the end rail to the support leg on the installed flat ramp section  
      Support Leg Assembly. Attach 2 feet to the opposite sides of the support leg using one  3½″× 5/16″ bolt, two  5′16″ washers and one 5/16″ locking nut (or equivalent fastener) installed through the respective holes at the center of each foot and the bottom of each leg.  
      Hybrid Modular Ramp System Section Installation. After assembly of the required incline modules and configured flat modules the assembly of the Hybrid Modular Ramp System can be assembled as incline and flat sections.  
      First Flat Ramp Section Installation. Start with the appropriate flat section at the highest point of egress/regress. Fasten this section to the residential structure with at least two 5/16″×5″ lag bolts and at least two 5/16″ flat washers (or equivalent fasteners) through any available holes on the base and side rails. Level any cross slopes before fastening. Be sure the section does not interfere with the operation of any doors. Take into account any weather conditions that may effect the door operation and what capabilities the user has when leaving a lip or raised edge at the section to structure junction. Next install the support legs. These are attached to the end of each section either at the flat rail end spindle or to the closest inside corner of the base extension with two #1 4×2″ self-tapping bolts through the 2 available lowest holes in the flat side rail end spindle/s and one #14×2″ self-tapping bolts through the available closest holes in the base extension (after this you should install the base to base extension bolt left out previously in the Base Extension Attachment section for this corresponding location). Be sure that the leg length selected does not cover the top hole on the flat rail spindle where the support leg is being attached. Completely level the section before final fastening. If a flat module has only 1 or no side rails then the upper spindle hole of the end rail is to be fastened to the joiner bar with one 2½″× 5/16″ bolt, two 5′16″ washers and one 5/16″ locking nut (or equivalent fastener).  
      Additional Flat Ramp Section Installation. Depending on configuration of the flat ramp module, the installation is conducted by following the related steps in Base Extension Attachment, End Rail Attachment and First Flat Ramp Section Installation.  
      First Incline Ramp Section Attachment. Mate the assembled incline module to the end of the installed flat section. When the spindles of the incline module are plumb in the vertical direction the opposite unattached en should be 5″ lower that the mating junction. First install two 3½″× 5/16″ bolts, four 5/16″ flat washers and two 5/16″ licking nuts (or equivalent fasteners) through the top spindle holes of the incline module and the mating flat section. Second install two 2½″× 5/16″ bolts, four 5/16″ flat washers and two 5/16″ licking nuts (or equivalent fasteners) through the two holes in the base of the incline module and the base of the mating flat section. Next install the support legs. These are attached to the end of each section either at the incline rail end spindle or to the closest inside corner of the base extension with two #14×2″ self-tapping bolts through the 2 available lowest holes in the flat side rail end spindle/s and one #14×2″ self-tapping bolts through the available closest holes in the base extension (after this you should install the base to base extension bolt left out previously in the Base Extension Attachment section for this corresponding location). Be sure that the leg length selected does not cover the top hole on the flat rail spindle where the support leg is being attached. Completely level the section before final fastening. If a mating flat section has only 1 or no side rails then the upper spindle hole of the incline side rail is to be fastened to the joiner bar with one 2½″× 5/16″ bolt, two 5′16″ washers and one 5/16″ locking nut (or equivalent fastener).  
      Additional Incline Ramp Section Installation. Mate the assembled incline module to the end of the installed incline section. When the spindles of the incline module are plumb in the vertical direction the opposite unattached en should be 5″ lower that the mating junction. First install two 3½″× 5/16″ bolts, four 5/16″ flat washers and two 5/16″ licking nuts (or equivalent fasteners) through the top spindle holes of the incline module and the mating incline section. Second install two 2½″× 5/16″ bolts, four 5/16″ flat washers and two 5/16″ licking nuts (or equivalent fasteners) through the two holes in the base of the incline module and the base of the mating incline section. Next install the support legs. These are attached to the end of each section either at the incline rail end spindle or to the closest inside corner of the base extension with two #14×2″ self-tapping bolts through the 2 available lowest holes in the flat side rail end spindle/s and one #14×2″ self-tapping bolts through the available closest holes in the base extension (after this you should install the base to base extension bolt left out previously in the Base Extension Attachment section for this corresponding location). Be sure that the support leg length selected does not cover the top hole on the flat rail spindle where the support leg is being attached. Completely level the section before final fastening. If a mating flat section has only 1 or no side rails then the upper spindle hole of the incline side rail is to be fastened to the joiner bar with one 2½″× 5/16″ bolt, two 5′16″ washers and one 5/16″ locking nut (or equivalent fastener).  
      Continuation Of Module Installation As Sections. Repeat the Installation process for all additional module to section instruction of the respective installation process listed previously.  
      Cross Bracing Installation. The cross bracing shall be fastened to each set of legs perpendicular to the direction of travel at all points where the base of the section is 15″ above grade. The cross bracing is attached to the opposite sides of each set of support legs creating an X pattern. Repeat this for every allowable section above 15″ from grade (as the base to grade distance increases the need for additional sets of cross bracing increases and shall be installed). These are fastened with two #14×2″ self-tapping bolts through the 2 available end holes in the cross brace  
      Return Rail Installation. Mate the return rails to the ends of the last installed section. With the spindles in the vertical direction facing out. First install one 3½″× 5/16″ bolts, two 5/16″ flat washers and one 5/16″ locking nuts (or equivalent fasteners) through the top spindle holes of the return rail and the mating ramp section. Next attach the return rail spindle with two #14×2″ self-tapping bolts through the 2 available lowest holes to the last support leg on the installed ramp section. Install four 1″ square tubing caps in the open ends of the top rails. Install 1″ square tubing caps in all exposed ends after the installation of all the sections is complete.  
      Wood Flooring Installation. Any type wood flooring that is able to support the loads required are acceptable for use. The following is an example: To use a plank or board simply cut the boards into the length required to fit into the width of the base of the ramp sections (perpendicular to the direction of travel). The lumber is to be recessed into the base of the section and should be level with the top surface of the section base. The lumber shall span across all three base support joists and be fastened to these joists with self-tapping screws (screw length shall not cause the screw to penetrate the bottom side of the base support joists upon installation). Lumber shall be installed into the base extension as a single board or piece recessed in at the longest dimension (perpendicular to the direction of travel). The lumber shall span across all five base extension support joists and be fastened to these joists with self-tapping screws (screw length shall not cause the screw to penetrate the bottom side of the base support joists upon installation).  
      Material Of Construction. The following is a materials and parts list for the Hybrid Modular Ramp. The entire Hybrid Modular Ramp is constructed of 1″-18 gage, electroplate galvanized and clear sealed square tubing. The accessories required are 1″ square tubing plug caps with an installed reveal of 3/16″. There are two different lengths of fastening bolts, 3½″× 5/16″ and 2½″× 5/16″ all related nuts and washers are 5/16″ a locking nuts and flat washers. Self-tapping bolts are #14×2″. Weld treatment consists of antioxidants (cold galvanization). All fasteners should be tightened as to ensure proper security and fastening.  
      Manufacturing processes of the Hybrid Modular Ramp. There are 4 processes in the production of all of the module components Cutting, Drilling, Welding and Weld treatment.  
      Cutting Procedure And Lengths. Only the Galvanized square tubing is required to be cut into increments. The cutting should be done by a mechanical means that does not leave burrs after cutting. All cuts shall be in lengths of tubing. Lengths and description consist of the following: 8″-base extension ends and joiner bars. 10″-base extension joists. 12″-leg support feet and return rail rails (top, middle, toe and bottom). 34″-spindles, base ends and base cross joists. 38″-end rail bottom rail. 40″-end rail rails (top, middle, toe and bottom). 59¾″-incline and flat rail top rails and base floor joists. 60″-base sides, flat and incline rails (middle, toe and bottom), base extension sides. 30″ to 75″ by 5″ increments-support legs and cross braces.  
      Drilling Procedure And Locations. All holes are drilled at a diameter of 7/16″ and extend trough both sides of the tubing and are always in the same plane. Holes should be drilled by a mechanical means does not leave burrs after drilling. 8″-base extension ends and joiner bars require 1 hole at each end at a distance of ½″ in from each end to the center of the hole. 12″-leg support feet require 1 hole 6″ in from either end to the hole center. 34″-spindles require 1 hole at each end a distance of 2½″ in from each end to hole center and an additional hole at 21½″ from either end (orientation of finished hole relativity is covered under the welding process). 34″-base ends require 1 hole at each end a distance of 2½″ in from each end to hole center. 38″ end rail bottom rails require 1 hole at each end a distance of 3½″ in from each end to hole center. 60″-base sides, flat and incline rail bottoms require 1 hole at each end a distance of 2½″ in from each end to hole center and 2 additional holes at 21½″ from each end. 30″ to 75″ by 5″ increments-support legs require 1 hole at either end at a distance of ½″ in from either end to the center of the hole. 30″ to 75″ by 5″ increments-cross braces require 1 hole at each end at a distance of ½″ in from each end to the center of the hole.  
      Welding Procedure And Placement. There are 7 different welded module components. The following is a list of these components and their assembly in the weld process. Left and right incline side rails, flat side rails, end rails, return rails, bases and base extensions. All welds are conducted at every overlapping intersection or end intersection on the working side with fillet welds. All welds extend for the full length of the intersection. All welding should be conducted in jigs to maintain consistency. The following description is for applications without a jug. All jig applications are determined by the jig itself, the same general order is assumed for jig applications.  
      Flat Side Rail Welding. Components of the flat side rail are two 34″ three hole spindles, one 34″ no hole spindle, two 59¾″ top rails, two 60″ no hole rails (middle and toe) and one 60″ four hole bottom rail. All intersections are perpendicular. Place the 60″ four hole bottom rail holes facing up on a flat surface. Place one 60″ no hole rails (toe) at 4″ on center, parallel and behind the 60″ four hole bottom rail and another (middle rail) at 18½″ on center, parallel and behind the 60″ four hole bottom rail. Place one 34″ three hole spindle to the far right, perpendicular and set back ½″ on top of these rails with the holes facing out and the holes closest to each other towards the top rail. Do the same on the opposite end of the rails with another 34″ three hole spindle. Flush up the bottom of the end of the spindles with the bottom of the 60″ four hole bottom rail. Place a 34″ no hole spindle parallel to the 3 hole spindles and equidistant from each (in the center). Place two 59¾″ top rails on top of each other and at the top end of the spindles. Raise the two 59¾″ top rails up ½″ so that the middle of the spindles is bisecting the point of which the two 59¾″ top rails touch each other. Square up all intersections and weld accordingly.  
      Left And Right Incline Side Rail Welding. The left and right incline side rails are mirror images of each other and have opposite planes as the working surface. Follow the same steps as in Flat Side Rail Welding except the unit must be racked as a parallelogram to achieve a slope of 1:12 when the rail is stood upright and the spindles are perpendicular to the work surface. This can be checked by plumbing the spindles and measuring the difference in height above the work surface at each end (there should be a 5″ difference).  
      Base Welding. Components of the base are two 34″ two hole base ends, one 34″ no hole base cross joist, three 59¾″ no hole base joists and two 60″ four hole sides. All intersections are perpendicular. Place the two 60″ four hole base sides parallel to each other at a distance of 34″ apart from inside to inside and the holes facing out on a flat surface. Place one 34″ two hole base end in between these at each end and flush up the ends with the holes facing out. Place a 34″ no hole base cross joist in the same orientation as the base ends and equidistant from each (in the center). Weld all intersections accordingly. Place one 59¾″ no hole base joist with the front face along the same plane as the back face of the 60″ four hole base side and on top of the base ends and base cross joist at each side of the base. Weld all intersections accordingly.  
      Base Extension Welding. Components of the base extension are two 60″ four hole base extension sides, two 8″ two hole base extension ends and five 10″ no hole base extension joists. All intersections are perpendicular. Place the two 60″ four hole base extension sides parallel to each other at a distance of 8″ apart from inside to inside and the holes facing out on a flat surface. Place one 8″ two hole base extension end in between these at each end and set back by ½″ the ends with the holes facing out. Weld all intersections accordingly. Place the five 10″ no hole base extension joists equidistantly on top and perpendicular to the two 60″ four hole base extension sides with the two end joists outward faces in the same plane as the two 8″ two hole base extension end inward faces. Weld all intersections accordingly.  
      End Rail Welding. Components of the end rail are two 34″ three hole spindles, one 38″ two hole bottom rail and three 40″ end rails (top, middle and toe). All intersections are perpendicular. Place the two 34″ two hole end rail spindles parallel to each other at a distance of 38″ apart from inside to inside and the holes facing up and the holes closest to each other towards the top rail on a flat surface. Place one 38″ two hole bottom rail in between these at the bottom and flush up the ends with the holes facing up. Place one 40″ no hole rail (toe) at 4″ on center, parallel and behind the 38″ two hole rail hole bottom rail and on top of the spindles and another (middle rail) at 18½″ on center, parallel and behind the 38″ two hole bottom rail. Place two 40″ top rails on top of each other and at the top end of the spindles. Lower the two 40″ top rails down ½″ so that the middle of the spindles is bisecting the point of which the two 40″ top rails touch each other. Square up all intersections and weld accordingly.  
      Return Rail Welding. Components of the return rail are two 34″ three hole spindles and five 12″ no hole return rail rails. The return rails are universal from left to right. They are placed in the same manner as in the instructions for the Flat Side Rail Welding section with the substitution of the 12″ rails for the 59¾″ top rails and 60″ middle, toe and bottom rails.