US20060261623A1

US20060261623A1 - Compact truck tailgate and general purpose utility ladder

Info

Publication number: US20060261623A1
Application number: US11/436,081
Authority: US
Inventors: John Kuznarik
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-05-20
Filing date: 2006-05-18
Publication date: 2006-11-23
Also published as: US20060261622A1; US7240947B2; MX2007014547A; WO2006127548A2; WO2006127548A3; CA2609105A1; EP1882077A2

Abstract

An exemplary embodiment sets forth an apparatus, including a non-collapsible single unit stair comprising: a pair of opposing side rails supporting at least a top step and a bottom step; a coupler adapted to couple the apparatus to an edge of a horizontal surface; and a height adjustable user-support arm, coupled to one of the side rails with a rotatable coupling, wherein the user-support arm is moveable between a support position and a storage position.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patent application Ser. No. 11/133,353, filed May 20, 2005, the entire content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates generally to ladders, and more particularly, to a ladder suitable for use as a ladder for vehicles having a tailgate or flatbed, and as a general purpose free-standing ladder.
2. Related Art
Pickup tailgate-type vehicles, for example, pickup trucks, sport utility vehicles (SUV), and station wagons, in today's world have become a vehicle of choice for a variety of reasons that were not as apparent in the past. A vehicle with a tailgate was considered a “work” type vehicle used in construction, farming, and industry.
Now there are extended cabs, four-door models with luxurious interiors with many features that were previously only found in fine automobiles. Today's SUVs, vans, station wagons, and pick-up trucks are broadly used for tailgate parties, at car races, ballgames, outdoor concerts, beach parties, and many other outdoor activities in addition to their traditional work-related uses.
Unfortunately, accessing a tailgate or flatbed of a vehicle can be quite an obstacle for many people. A major challenge is accessing the bed of the vehicle. It can be very difficult to reach over the side rails of the bed of a vehicle in order to retrieve an object, or to climb into the truck bed without the aid of a step assembly. It is even more difficult to exit the truck bed, whether a person is carrying something or simply trying to get down, because of the height of the tailgate from the ground.
The use of step assemblies for tailgate access is known in the art. However, conventional step assemblies have various shortcomings that make them an imperfect solution to the problem of tailgate and truck bed access.
Some tailgate step assemblies are mounted permanently to a base on the inside of the tailgate, which always encumbers the tailgate. Users of such tailgate step assemblies often have to exercise additional care not to trip over the permanently mounted assembly. Others are mounted permanently to the outside of the tailgate, which exposes the ladder to damage and theft.
Most tailgates or flatbed type vehicles have a standardized distance from the ground to the tailgate or flatbed of approximately 28 inches, 30 inches, 33 inches, 37 inches, or 49 inches. Some conventional tailgate step assemblies have only a single step, which does little to bridge the height gap from tailgate to ground. Still other tailgate step assemblies have very narrow steps, or steps with large height separations, which are difficult for the elderly or disabled to use, as well as tiring for those using the assembly for an extended period of time. For example, virtually all types of ladders and staircase type assemblies in today's marketplace have a step or rung riser height of 9.5 inches to 12 inches, while typical building staircases have riser heights of around 6 to 8 inches.
Most conventional tailgate step assemblies have no support arms. In tailgate step assemblies that do have support arms, the support arms are very short. Short support arms are essentially useless, particularly when leaving the vehicle bed. Most support arms are not permanently attached to the step assembly, which makes them very easy to forget or misplace.
Still other tailgate step assemblies have many moving parts or are collapsible, which tends to make them less stable and prone to malfunction.
Further, no conventional tailgate step assemblies are useable as free-standing step assemblies. If the user of the tailgate step assembly also needs a ladder or step assembly, for example, at a job site, the user would have to bring an extra ladder for that purpose.
What is needed then is an improved tailgate step assembly that overcomes shortcomings of conventional solutions.

SUMMARY OF THE INVENTION

Accordingly, an exemplary embodiment of the present invention includes a non-collapsible staircase-type step assembly that can be coupled to an outside vertical edge of a tailgate or vehicle flatbed, and that has height adjustable support arms. The step assembly may also have telescoping adjustable feet at the underside of the bottom step. The step assembly can be free-standing with a pair of ladder support legs, designed to steady and position the ladder steps (when in the user open position) in a precise horizontal position ready for use. The ladder support legs may also have telescoping adjustable feet attached to the bottom end of the legs. A pair of wheels or casters at the backside of the siderails at the bottom end of the ladder may allow for easy movement of the ladder in a closed position. When coupled to a tailgate, the ladder may leave the tailgate totally clear and unencumbered. The ladder may be easily removed for its many other diversified uses, and is not limited to just being attached to a tailgate or vehicle flatbed.
Embodiments of the present invention may provide for much safer access to the tailgate of a pickup truck when the tailgate is in the horizontal open position and/or the flatbed of a vehicle. With an exemplary riser height of 7 to 8 inches, embodiments of the present invention provide a very uniform standard type design to fit all vehicle tailgate or flatbed configurations.
The user comfort support railings may be permanently attached to the step assembly so they cannot be forgotten or left behind, and may be height adjustable.
In an exemplary embodiment of the present invention, an apparatus may include a non-collapsible single unit stair comprising: a pair of opposing side rails supporting at least a top step and a bottom step; a coupler adapted to couple the apparatus to an edge of a horizontal surface; and a height adjustable user-support arm, coupled to one of the side rails with a rotatable coupling, wherein the user-support arm is moveable between a support position and a storage position.
In one exemplary embodiment of the present invention, the apparatus is coupled to the edge of the horizontal surface, the apparatus does not encumber the horizontal surface substantially.
In one exemplary embodiment of the present invention, the apparatus may further include a second height-adjustable user-support arm.
In one exemplary embodiment of the present invention, the apparatus may further include a pair of support legs, each having a top end coupled with a rotatable leg coupling to a different side rail and a bottom end for resting on a support surface, wherein each support leg is moveable between an extended support position and a folded storage position.
In one exemplary embodiment of the present invention, the support legs are extended, the apparatus is capable of standing freely without being coupled to the horizontal surface.
In one exemplary embodiment of the present invention, the bottom end of each of the pair of support legs further comprises a height-adjustable foot.
In one exemplary embodiment of the present invention, each of the pair of support legs may further include a wheel coupled to the bottom end.
In one exemplary embodiment of the present invention, the apparatus is storable against a vertical surface.
In one exemplary embodiment of the present invention, the apparatus may further include a height-adjustable foot coupled to a bottom end of each of the side rails.
In one exemplary embodiment of the present invention, a wheel may be coupled to a bottom end of each of the side rails.
In one exemplary embodiment of the present invention, each step is approximately 15 inches wide.
In one exemplary embodiment of the present invention, each step is separated vertically from an adjacent step by approximately 7 to 8 inches.
In one exemplary embodiment of the present invention, the user-support arm is adjustable from a height of approximately 15 inches to a height of approximately 32 inches above the top step.
In one exemplary embodiment of the present invention, the apparatus may further include a utility tray coupled to the two user-support arms.
In one exemplary embodiment of the present invention, the coupler may include a fastening slot adapted to receive a bolt head extending from the edge of the horizontal surface.
In one exemplary embodiment of the present invention, the fastening slot may be disposed in the user-support arm, or top step.
In one exemplary embodiment of the present invention, the rotatable leg coupling may include: a pair of rotor limiting plates separated by a separation sleeve, each rotor-limiting plate having a user-ready slot and a storage slot in an outer edge, wherein an outer side of one rotor limiting plate is coupled to the side rail and an outer side of the other rotor limiting plate is coupled to the support leg; fastening means disposed substantially within the separation sleeve to fasten the pair of rotor limiting plates to each other, wherein the fastening means forms a pivot point for the support leg; a locking pin coupled to the support leg and adapted to fit in the user-ready and the storage slots; and tension adjusting means adapted to allow the locking pin to move radially inward and outward with respect to the pivot point.
In one exemplary embodiment of the present invention, the rotatable coupling may include a pair of rotor limiting plates separated by a separation sleeve, each rotor limiting plate having a user-ready slot and a storage slot in an outer edge, wherein an outer side of one rotor limiting plate is coupled to the side rail and an outer side of the other rotor limiting plate is coupled to the user-support arm; fastening means disposed substantially within the separation sleeve to fasten the pair of rotor limiting plates to each other, wherein the fastening means forms a pivot point for the user-support arm; a locking pin coupled to the user-support arm and adapted to fit in the user-ready and the storage slots; and tension adjusting means adapted to allow the locking pin to move radially inward and outward with respect to the pivot point.
In another exemplary embodiment of the present invention, a rotatable coupling may include: a pair of rotor limiting plates separated by a separation sleeve, each rotor limiting plate having a user-ready slot and a storage slot in an outer edge, wherein an outer side of one rotor limiting plate is adapted to be coupled to a fixed support and an outer side of the other rotor limiting plate is adapted to be coupled to a rotatable member; fastening means disposed substantially within the separation sleeve to fasten the pair of rotor limiting plates to each other, wherein the fastening means forms a pivot point for the rotatable member; a locking pin coupled to the rotatable member and adapted to fit in the user-ready and the storage slots; and tension adjusting means adapted to allow the locking pin to move radially inward and outward with respect to the pivot point.
In one exemplary embodiment of the present invention, the tension adjusting means may include a spring coupled at one end to the separation sleeve and at the opposite end to the locking pin.
In one exemplary embodiment of the present invention, the tension adjusting means may include: a spring adapted to be coupled at one end to the fixed support and at the opposite end to the rotatable member.
In one exemplary embodiment of the present invention, the rotatable coupling may include a curved slot disposed in said side rail; a rotation rivet coupled to said user support arm and disposed in said curved slot, adapted to move freely in said curved slot; a coupling adapted to couple said user-support arm to said side rail and to allow said user-support arm to rotate between said support position and said storage position; and means for preventing said user-support arm from moving when in said support position or said storage position.
In another exemplary embodiment of the present invention, an apparatus may include: a non-collapsible single unit stair comprising a pair of opposing side rails supporting at least a top step and a bottom step; and a roller system adapted to attach said apparatus adjacent to a substantially horizontal surface, said roller system providing for movement of the apparatus between a user-ready position and a storage position under said substantially horizontal surface.
In one exemplary embodiment of the invention, the apparatus may further include a height adjustable user-support arm, coupled to one of said side rails with a rotatable coupling, wherein said user-support arm is moveable between a support position and a storage position.
In one exemplary embodiment of the invention, the apparatus may further include a second height adjustable user-support arm.
In one exemplary embodiment of the invention, the roller system may include a pair of spaced-apart travel rails attached to said horizontal surface; and a pair of rollers attached to said single unit stair and located on said travel rails. The roller system can be adapted to connect to the underside of a vehicle, such as a trailer.
In one exemplary embodiment of the invention, the apparatus may further include an actuator mechanism adapted to move said apparatus between the user-ready position and the storage position. The actuator mechanism can comprises a pneumatic cylinder, a motor driven chain and sprocket arrangement, or any other conventional drive means.
In one exemplary embodiment of the invention, the apparatus may further include an adjustable bumper bracket associated with said single unit stair, said adjustable bumper bracket adapted to connect to a structure associated with the substantially horizontal surface, such as the top horizontal portion of a trailer bumper bar. The adjustable bumper bracket retains said single unit stair in the user-ready position. The adjustable bracket can be raised or lowered to adjust at least the vertical height of said single unit stair with respect to the substantially horizontal surface when said single unit stair is in the user-ready position. In one exemplary embodiment of the invention, the apparatus may include at least one non-collapsible ladder brace connecting said adjustable bracket to said single unit stair. In another exemplary embodiment, a secondary non-collapsible ladder brace may be attached to the first ladder brace to connect said adjustable bumper bracket to said single unit stair.
In another exemplary embodiment of the invention, the apparatus may further include: a non-collapsible single unit stair comprising a pair of opposing side rails supporting at least a top step and a bottom step; at least one hinge adapted to connect said apparatus to an edge of a horizontal surface, said hinge providing for movement of said single unit stair between a user-ready position and a storage position; and a height adjustable user-support arm, coupled to one of said side rails with a rotatable coupling, wherein said user-support arm is moveable between a support position and a storage position.
In one exemplary embodiment of the invention, the apparatus may further include a second height adjustable user-support arm.
In one exemplary embodiment of the invention, the apparatus may include an angle iron adapted to mount to said edge of said horizontal surface. One side of said hinge can be mounted on said angle iron.
In one exemplary embodiment of the invention, the apparatus may further include a ladder holding plate and at least a second hinge attaching said ladder holding plate to said angle iron.
In one exemplary embodiment of the invention, said horizontal surface is part of a vehicle, for example, the upper horizontal surface of an open tailgate.
In another exemplary embodiment of the invention, the apparatus may include: a non-collapsible single unit stair comprising a pair of opposing side rails supporting at least a top step and a bottom step, and a backdrop located behind and above the top step of the stair; an angle iron adapted to mount to an edge of said horizontal surface, said angle iron comprising a first leg extending substantially parallel to the horizontal surface, and a second leg extending substantially perpendicular to the horizontal surface; a ladder holding plate; at least one first hinge connecting said single unit stair to said angle iron; and at least one second hinge connecting said ladder holding plate to said angle iron; wherein surface engagement between said angle iron and said backdrop supports said single unit stair in said user-ready position.
Further features and advantages of the invention, as well as the structure and operation of various embodiments of the invention, are described in detail below with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the invention will be apparent from the following, more particular description of exemplary embodiments of the invention, as illustrated in the accompanying drawings wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.
FIG. 1 depicts an exemplary side view of a four-step non-collapsible one-piece staircase type ladder in the open position attached to a truck tailgate according to an exemplary embodiment of the present invention;
FIG. 2 depicts an exemplary side view of an exemplary embodiment of a four-step version of the invention in a free-standing user-ready position, according to the present invention;
FIG. 2A depicts the ladder shown in FIG. 2, with the user-support arms in the storage position;
FIG. 3 depicts an exemplary front view of the ladder in FIG. 2;
FIG. 4 depicts an exemplary top view of an exemplary top step of an embodiment of the present invention where the ladder attaches to the tailgate from slots provided in the user-support arms;
FIG. 5 depicts an exemplary top view of a top step of an embodiment of the present invention where the ladder attaches to the tailgate from slots provided in the vertical backdrop behind the top step;
FIG. 6 depicts an exemplary isometric view of the ladder shown in FIG. 1, secured to an outside adjacent vertical face of a tailgate in the horizontal position, by an exemplary fastening means or bolts;
FIG. 7 depicts an exemplary side view of the ladder shown in FIG. 1 coupled to a vehicle having a tailgate one step height higher than the top step of the ladder;
FIG. 8 depicts an exemplary side view of the ladder shown in FIG. 1, secured to a flatbed vehicle with fastening means provided in the user comfort support railings;
FIG. 9 depicts an exemplary front view of a ladder secured to the furthest outside vertical section of a deck at an emergency door exit of a bus type vehicle such as a school bus;
FIG. 10 depicts an exemplary side view of an exemplary five step version of the staircase type ladder in the open position which may be standing or secured adjacent to the bed or end of an enclosed tractor trailer like vehicle, and the staircase type ladder in an exemplary storage position under the bed of trailer;
FIG. 11 depicts an exemplary top view of an exemplary embodiment of the present invention mounted to inside of closed truck tailgate in an exemplary concealed storage position;
FIG. 12 depicts an exemplary side view of the stored ladder shown in FIG. 11;
FIG. 13 depicts an exemplary side view of a first exemplary embodiment of a rotatable coupling which may attach a support leg to the ladder;
FIG. 14 depicts an exemplary side view of a first exemplary embodiment of a rotatable coupling which may attach a user-support arm to the ladder;
FIG. 15 depicts an exemplary front view of the rotatable couplings shown in FIGS. 13 and 14;
FIG. 16 depicts an exemplary isometric view of the rotatable couplings shown in FIGS. 13 and 14 which may be used for a support leg and a user-support arm, respectively;
FIG. 17 depicts an exemplary side view of a second exemplary embodiment of a rotatable coupling attaching a support leg to the ladder;
FIG. 18 depicts an exemplary side view of a second exemplary embodiment of a rotatable coupling attaching a user-support arm to the ladder;
FIG. 19 depicts an exemplary front view of the rotatable couplings shown in FIGS. 17 and 18, which may be used for a support leg and a user-support arm, respectively;
FIG. 20 depicts an exemplary isometric view of the rotatable couplings shown in FIGS. 17 and 18, which may be used for a support leg and a user-support arm, respectively;
FIG. 21 depicts an isometric view of a one-piece solid ladder without attachments;
FIG. 22 depicts a rear view of an exemplary top step of the invention showing exemplary rotatable couplings;
FIG. 23 depicts a side view of a third exemplary embodiment of a rotatable coupling used to couple a user-support arm to the side rail;
FIG. 23A is an enlarged view of the rotatable coupling shown in FIG. 23;
FIG. 24 depicts a back view of an exemplary embodiment of a rotatable coupling used to couple a user-support arm to the side rail as shown in FIGS. 23 and 23A;
FIG. 25 depicts an exemplary side view of an exemplary staircase type ladder of the present invention in the user-ready position which may be secured to the bed or end of an enclosed tractor trailer like vehicle, and the staircase type ladder in an exemplary storage position under the bed of the trailer;
FIG. 26 depicts an exemplary rear view of an exemplary staircase type ladder in an open position (left) secured adjacent to the bed or end of an enclosed tractor trailer like vehicle, and in two different closed positions (center, right) under the bed of the trailer;
FIG. 27 depicts an exemplary side view of an exemplary staircase type ladder in an open position and attached to an open tailgate of a pickup type vehicle, and also in an exemplary storage position inside a bed of a pickup type vehicle;
FIG. 28 depicts an exemplary isometric view of an exemplary staircase type ladder mounted via hinges to the top face of an open tailgate of a pickup type vehicle;
FIG. 29 depicts an exemplary side view of an exemplary staircase type ladder of the present invention in the user-ready position which may be secured adjacent to the bed or end of an enclosed tractor trailer like vehicle, and the staircase type ladder in an exemplary storage position under the bed of the trailer;
FIG. 30 depicts an exemplary side view of an exemplary staircase type ladder of the present invention mounted to a trailer frame and including an exemplary pneumatic cylinder that can permit movement of the ladder from an open position to a storage position under the trailer and visa versa; and
FIG. 31 depicts an exemplary top view of an exemplary staircase type ladder of the present invention mounted to a trailer frame and including an exemplary pneumatic cylinder that can permit movement of the ladder from an open position to a storage position under the trailer and visa versa.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE PRESENT INVENTION

An exemplary embodiment of the invention is discussed in detail below. While specific exemplary embodiments are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations can be used without departing from the spirit and scope of the invention.
FIG. 1 depicts a side view of a first exemplary embodiment of non-collapsible staircase-type ladder 1. The ladder 1 may include a non-collapsible single unit stair that may include a pair of opposing side rails 5 supporting four steps 6. Although the side rails 5 and steps 6 are discussed as separate components, exemplary embodiments of the present invention may comprise a single unit of side rails 5 and steps 6, formed, for example, from a single molded piece of plastic, fiberglass, aluminum plate, diamond plate, or stainless steel plate, etc., forming the side rails and steps. The ladder 1 may further include a pair of support legs 12, and one or two telescoping user-support arms 16. The stability of ladder 1 may be improved with a collapsible cross-brace 15 which may be coupled to side rail 5 and support leg 12.
The ladder 1 may be coupled to the outermost edge 3 of an open truck tailgate 4. The coupling mechanism may include, for example, tailgate-to-ladder fastening bolts 25 that may protrude from edge 3 of the tailgate 4. See FIGS. 4 and 5 below. Slots (not shown in FIG. 1, but see slots 17, 10 described further below with reference to FIGS. 3 and 6, respectively) may be provided in, e.g., the user-support arms 16, or in the back of the top step 6, that may be operative to slide over the fastening bolts 25 and secure the ladder 1 to the tailgate edge 3. In this first embodiment, when the tailgate 4 is secured to slots in the back of the top step of the ladder 1, the top step may be at the same elevation as the open tailgate 4. The fastening bolts 25 may move freely up and down while positioned in the slots, while the ladder 1 may stay immobile on the ground. Coupling the ladder 1 to the edge 3 of a tailgate 4 may leave the horizontal surface of the tailgate 4 unencumbered for access of people or materials. The user-support arm 16 and support leg 12 are also shown in a storage position on the outside of side rail 5, for reference.
When ladder 1 is in the access user ready position, as shown in FIG. 1, the slots may be centered at the same center as fastening bolts 25 when tailgate 4 is in the open horizontal position. In an exemplary embodiment, to achieve this alignment, for example, on uneven ground, the ends of the support legs 12 may be equipped with adjustable telescopic feet 13, and the inside face of the side rails 5 or the inside front face of the bottom step 6 may be equipped with adjustable telescopic feet 8. In an exemplary embodiment, the casters 14 may be installed on an outside bottom surface of the side rails 5 to allow the ladder 1 to be rolled about in a closed position.
FIG. 2 depicts an exemplary side view of ladder 1 in a free-standing, user-ready position, with telescoping user-support arms 16 fully extended, according to an exemplary embodiment. A utility tray 20 may be coupled to the upper ends of user-support arms 16 and ready for use. Height-adjustable feet 8 and 13 together may permit ladder 1 to be leveled when open on an uneven surface. In addition, in an exemplary embodiment, spring-actuated casters 19 may be coupled to the lower ends of support legs 12 or on the inside face of side rails 5, or on the inside front face of bottom step 6. In an exemplary embodiment, casters 19 may permit the operator to roll ladder 1 from one area to another without having to open and close ladder 1. This feature may be useful for trades people using the ladder in areas where the ladder may roll easily on the floor. The feature also makes it possible to move the ladder with any tools and supplies in use aboard the ladder without having to fold and carry the ladder and find another means for moving the tools and supplies. Support leg 12 is also shown in a storage position underneath steps 6.
FIG. 2A depicts an exemplary side view of ladder 1 in a free-standing, user-ready position, with user-support arms 16 in a storage position, where they can be mounted to an outside face of the side rails 5, which permits use of the ladder without the user-support arms 16. Support leg 12 is also show in a storage position against the outside of side rail 5.
FIG. 3 depicts a front view of ladder 1. Ladder 1 may provide a large opening 23 in the stair risers, which may allow the user's entire foot, or both feet, to be on one step 6. In an exemplary embodiment, each step may be about fifteen inches wide and may be about 9 inches deep. In an exemplary embodiment, each step may be vertically separated from an adjacent step by about seven to eight inches. In an exemplary embodiment, height-adjustable feet 13 may be attached to support leg 12 by matching up holes in leg 12 with holes on an insert piece on height-adjustable foot 13. Feet 8 may be adjusted by matching up holes in a foot 8 with holes on an insert piece, and by the insertion of a dimpled locking spring device 30. The insert piece may be on the inside face of the bottom step 6 or on the inside face of side rails 5. Foot 8 may be adjusted and secured at a desired position. The height of user-support arm 16 may be adjusted in a similar manner, or by any other securable, adjustable means. Slots 10 are indicated where they may be positioned, e.g., in the back of the top step 6. Slots 17 are shown in the back of user-support arms 16, although slots 17 may not be visible from the front of ladder 1. The use of slots 10 or slots 17 depends on the alignment of the tailgate or flatbed with the ladder. For example, if the tailgate or flat bed is higher than the top step 6, then slots 17 are used. If the tailgate or flatbed is at the same height as the top step 6, then slots 10 are used.
FIG. 4 depicts an exemplary top view of a top step of an exemplary embodiment of the present invention where the ladder may be attached to the tailgate from the user-support arms 16. The ladder 1 may be coupled to the vertical face 3 of tailgate 4, for example, by sliding slots 17, disposed in user-support arms 16, over tailgate-to-ladder fastening bolts 25 protruding from the vertical face 3 of open tailgate 4, or of a vehicle flatbed.
FIG. 5 depicts an exemplary top view of a top step of an embodiment of the present invention where the ladder may attach to the vertical face 3 of the open tailgate from the vertical backdrop behind the top step 6. Slots 10 may be disposed in the back of the top step that may be adapted to slide over fastening bolts 25.
FIG. 6 depicts an isometric view of the ladder shown in FIG. 1, secured to an outside face 3 of a tailgate 4 in the horizontal position, by fastening means which may be provided in the vertical back drop behind the top step 6. Fastening the ladder 1 to the tailgate 4 at the top step may allow the top step to be substantially level with the horizontal tailgate.
FIG. 7 depicts a side view of the ladder coupled to a tailgate, with fastening means provided in the user-support arms 16, where the tailgate is higher than the top step of the ladder.
FIG. 8 depicts a side view of the ladder secured to an exemplary flatbed trailer 9 with fastening means provided in the user-support arms 16. The fastening means may be, for example, bolts or other means described in relation to FIG. 4, or any of various conventional couplers, fasteners, or connectors. When the ladder is fastened by the user-support arms 16, the top step of the ladder may be positioned one step-height below the flatbed or tailgate height.
FIG. 9 depicts an exemplary front view of a ladder 100 secured to the furthest outside vertical section of the deck at the emergency door exit of a school bus type vehicle. The user-support arms 16 are shown stowed in a storage position.
FIG. 10 depicts an exemplary side view of an exemplary five-step embodiment 102 of the staircase type ladder in an open position which may be secured or standing adjacent to the bed of an enclosed tractor trailer like vehicle. Also shown is the staircase type ladder 102 in a storage position under the bed of the trailer.
FIG. 11 depicts a top view of ladder 1 which may be mounted to the inside of a closed truck tailgate in the concealed storage position. User-support arm 16 and support leg 12 are shown in a storage position on the outside face of side rail 5. FIG. 12 depicts an exemplary side view of the stored ladder shown in FIG. 11. The folded ladder assembly may be mounted, for example, by means of retractable storage brackets 7 coupled to the outer face 3 of tailgate 4 via fastening bolts 25.
FIGS. 13-15 show various exemplary views of a first exemplary embodiment of a rotatable coupling 200 that may be used to couple support leg 12 or user-support arm 16 to an exemplary ladder according to embodiments of the present invention. Hereinafter, the coupling may be described as being attached to support leg 12, however, the coupling may be coupled analogously to user-support arm 16, as shown, for example, in FIG. 14.
Support leg 12 may be mounted in between rotor limiting plates 36. Each rotor limiting plate 36 may have at least two slots disposed in its outer edge: a storage slot 31, 43, and a user-ready slot 38. The couplings shown in FIGS. 13 and 14 are substantially similar, however, the separation and angle between the user-ready slot and storage slot in a support leg coupling may be different from the separation and angle in a user-support arm coupling. Although only two slots are described in detail below, any number of slots could be provided in the rotor limiting plates 36 to allow more flexibility in positioning the support legs 12 and the user-support arms 16. Rotor limiting plates 36 may be substantially semi-circular, or circular less a sector as illustrated, but are not limited to that shape.
A separation sleeve 41 may be placed between rotor limiting plates 36 and over a securing bolt 32. Separation sleeve 41 may be long enough to permit rotation of support leg 12 about separation sleeve 41. Support leg 12 may have a locking pin 34 mounted inside a hollow stanchion of support leg 12 that may penetrate the walls of support leg 12. Locking pin 34 may protrude from the outside face of support leg 12 for a length approximately equal to the thickness of the rotor limiting plate 36.
One end of a spring 33 may be coupled to locking pin 34, while the opposite end of spring 33 may be coupled to separation sleeve 41 in between rotor limiting plates 36. Spring 33 may be generally stretched and under tension at all times, resulting in locking pin 34 being held against the bottom of one of the user-ready or storage slots, as seen, e.g., in FIG. 13, or may be held against the outer edge of rotor limiting plates 36, as seen, e.g., in FIG. 14.
When locking pin 34 is in a slot, e.g., slot 38, a gap may be created between the bottom of contoured spring slot 40, and the bottom of separation sleeve 41. This gap may be approximately equal to the diameter of stationary locking pin 34. When the user desires to move support leg 12, or user-support arm 16, from one position to another, support leg 12 may be pulled such that locking pin 34 comes out of the slot where it rests. While locking pin 34 is out of its current slot, support leg 12 may be rotated to another slot while locking pin 34 slides along the outer edge of rotor-limiting plates 36. Pulling support leg 12 to remove locking pin 34 from a slot temporarily closes the gap.
FIG. 16 is described further below following FIG. 19.
FIGS. 17-19 show various exemplary views of second exemplary embodiment of a rotatable coupling 300 that may be used to couple support leg 12 or user-support arm 16 to an exemplary ladder according to embodiments of the present invention. Hereinafter, the coupling is described as being attached to support leg 12, however, the coupling 300 may be coupled analogously to user-support arm 16, as shown, for example, in FIG. 18.
Support leg 12 may be coupled to a rotary plate 45 secured in between rotor limiting plates 36. A spring 33 may be secured at one end to support leg 12, for example, in a hole 47. The other end of spring 33 may be secured to rotor limiting plate 36, for example, in a hole 46. A configured slot 44 in rotary plate 45 may provide a gap between the bottom of the separation sleeve 41 and the bottom of the configured slot 44 approximately equal to the diameter of locking pin 48. This gap may permit locking pin 48 to move to the outside edge of rotor limiting plates 36 when more pressure is applied to spring 33, e.g., when support leg 12 is pulled on in the direction of the line of spring 33.
FIG. 16 shows an isometric view of part of an exemplary embodiment of the present invention, with user-support arm 16 secured to an outside face side rail 5 with rotatable coupling 200. Further, support leg 12 is shown secured to the inside face of side rail 5 with rotatable coupling 200. Support legs 12 may also be secured to the outside face of side rails 5 at a point just below user-support arms 16. User-support arm 16 and support leg 12 may be rotated from a user ready slot to a storage position slot or vice versa. Either of the embodiments shown in FIGS. 13-15 or FIGS. 17-19 may be used to couple support legs 12 or user-support arms 16 to the ladder 1. Additionally, other coupling mechanisms may also be used. FIG. 20 is analogous to FIG. 16, but for rotatable coupling 300.
FIG. 21 shows an isometric view of a one-piece non-collapsible single-unit stair, without any additional components. The stair may be made in a mesh style, or solid. The stair may be made from, e.g., aluminum, diamond plate, stainless steel, fiberglass, nylon or plastic, formed or stamped from a one piece configuration. The steps of the stair may be perforated to prevent liquids from pooling on the steps. The steps may also have a non-skid surface.
FIG. 22 depicts a rear view showing the back side of the top step 6. The rotatable couplings 200 and 300, respectively, on the user-support arms 16 are shown coupled to the outside face of side rails 5, while the rotatable couplings 200 and 300 for the support legs 12 may be coupled to the inside face of side rails 5. The rotatable couplings for the support leg 12 may be coupled in the alternative to the outside face of side rails 5.
FIG. 23 depicts a side view of a third exemplary embodiment of a rotatable coupling used to couple a user-support arm 16 to the side rail 5. FIG. 23A is an enlarged view of the rotatable coupling shown in FIG. 23. FIGS. 23 and 23A show the user-support arm in the user ready and storage positions. The user-support arm 16 is pulled against the outside face of side rail 5 by a rotation rivet 37 that holds user-support arm 16 and side rail 5 together. User-support arm 16 may also be held in position with a rivet 26, whose shaft may pass through user-support arm 16 and curved slot 39. Slot 39 may be wide enough to permit penetration of the shaft of rivet 26. Rivet 26 may be disposed in a hole 27 in user-support arm 16. The shaft of rivet 26 may be long enough to extend from the outside face of user-support arm 16 to the inside face of slot 39 in side rail 5. The disposition of rivet 26 in slot 39 may permit the rotation of user-support arm 16 between a user-ready and a storage position. User-support arm 16 may be secured in position to side rail 5 by a thumbscrew 35 through a hole 50 (user ready position) or hole 51 (storage position), both in side rail 5. When in the storage position, user-support arm 16 may be further secured with a holding bracket 24 coupled to side rail 5.
FIG. 24 depicts a back view of the user-support arm 16 in a user ready position and secured to the outside face of side rail 5. Hole 50 in side rail 5 receives thumbscrew 35 to secure user-support arm 16. The shaft of rivet 26 fits within slot 39, and is held in slot 39 by the ends of the rivet 26.
Referring to FIG. 25, another exemplary embodiment of a ladder 5 according to the present invention is shown. FIG. 25 is a side view of a five step version of ladder 5 shown in the user-ready position as well as in the storage position. In the exemplary embodiment shown, the top step of ladder 5 is one step below the deck of the trailer.
When ladder 5 is in the user-ready position, it can be held there by an adjustable bumper bracket 50 that can be secured to a first ladder bracket 39 and/or a secondary, non-collapsible ladder bracket 52. According to one exemplary embodiment, the unit comes with the optional secondary bumper bracket 52 attached, although it can easily be removed if the trailer horizontal bumper bar is too high to permit its use.
The secondary, non-collapsible ladder bracket 52 may be necessary when the horizontal trailer bumper bracket 126 is approximately 21 inches above ground level. Vertical sections of the ladder brackets 39, 52 may be constructed of hollow tubing (e.g., rectangular or square hollow tubing) so that bumper bracket 50 can be located inside the tubing and moved up or down for proper vertical alignment.
Ladder 5 can be held in place by one or more rollers 27 that allow ladder 5 to move freely from an open user-ready position to a storage position under trailer, both of which are shown. Rollers 27 can be mounted over a rod 60 that snugly passes through side rails located behind ladder 5. The rollers 27 can rest between ladder roller tracks 37 that are mounted under truck bed framing 59, for example, by one or more adjustable hangers 35 that are welded or bolted to the truck bed framing 59. Hanger(s) 35 can be designed to be adjustable in position and/or to conform to the truck bed framing 59. Replaceable ladder rollers 27 may be permanently mounted in between roller rails 37. Threaded rod can be attached to each hanger 35 to allow roller rails 37 to be adjusted vertically to allow for exact vertical location of the horizontal position of the ladder's steps. One of ordinary skill in the art will know that the rollers 27, roller rails 37, rail hanger(s) 35, and related components may be of a different style or type than what is shown.
Once ladder 5 steps have been set at the desired vertical position when in the user-ready position, the bottom horizontal section of adjustable bumper bracket 50 can be positioned to rest firmly against the top horizontal section of horizontal bumper rail 126, and then secured to non-collapsible secondary ladder bracket 52, for example, using bolts. A slide pin 64 can be mounted to the outside vertical face of the adjustable bumper bracket 50. Slide pin 64 can be extended downward to the point where it will rest against outside vertical face portion of the horizontal bumper rail 126, and hold ladder 5 in the user ready position. Since the horizontal bumper rail 126 may be located at different heights depending on the vehicle, adjustable bumper bracket 50 can be adjusted vertically to suit various locations.
When ladder 5 is in the user-ready position, rollers 27 can drop into a substantially vertical slot defined in rails 37. Engagement between the rollers 27 and the slot can retain the ladder 5 in the user-ready position. The length of the vertical slot can be substantially equal to the vertical length of the portion of the pin in slide bolt 64 that protrudes over and rests against the outside vertical face of bumper rail 126. As a result, to place ladder 5 back into the storage position, the user can first raise rollers 27 upwards out of the vertical slot and into the horizontal track portion of rails 37. From this point, the user can push ladder 5 straight back until the top step clears the lower horizontal surface of angle iron 56, at which point, the ladder 5 can be raised by lifting up on the bottom step and pushing ladder 5 back into the desired storage position. According to this exemplary embodiment, it may not be necessary to cut a clearance into channel iron 56 for ladder 5. According to an alternative embodiment, the vertical slots can be omitted from the rails 37, for example, by providing a cut-out in channel iron 56 that is large enough to allow the top step of ladder 5 to slide back under the trailer when ladder 5 has been raised enough for the pin that has been left in the open position in slide bolt 64 to clear the top horizontal section of horizontal bumper 126. This embodiment may be preferable if the user does not want to raise and lower the pin in slide bolt 64 every time he uses the ladder 5. In the case where rails 37 come pre-formed with the vertical slot, the vertical slot can be blocked with an optional plate 63 (e.g., bolted or riveted to the rails 37) if the user wants to engage and disengage the pin in slide bolt 64 every time he uses the ladder 5.
When not in use, ladder 5 may be rolled back under the trailer with its bottom step resting on the horizontal bumper rail 126, or alternatively, attached to the other end of the roller rails or the trailer framing with S-hooks or similar devices. The user support railings 16 can be attached to the side rails of ladder 5 when it is in the storage position.
FIG. 26 is a front view of the five step ladder of FIG. 25 located behind a trailer. On the left side of the figure, the ladder is located in the user-ready position, with rollers 27 secured in ladder roller slots between roller rails 37 and attached to hangers 35 secured to trailer framing 59. The ladder 5 can be held firmly in the user-ready position by the adjustable bumper bracket 50, which can be raised or lowered to compensate for the vertical height of the horizontal bumper rail 126. The bottom horizontal surface of the bumper bracket 50 can be mounted tightly against the upper surface of horizontal bumper rail 126 after being set at the proper elevation, for example, using bolts or other fasteners. The bumper bracket 50 can be attached to the ladder 5 via the first ladder bracket 39, and/or second ladder bracket 52, for example, by bolts, rivets, or other fasteners. The lower horizontal surface of bumper bracket 50 can rest firmly against the upper horizontal section of trailer bumper rail 126. Slide bolts 64 may be installed on the bottom vertical section of adjustable bumper bracket 50 in such a position that when the slide bolts are released, they will rest firmly against the outside vertical section of bumper rail 126, and hold ladder firmly in the user-ready position.
Still referring to FIG. 26, ladder 5 is shown in the center of the figure in a storage position under the truck bed. Ladder 5 is located between two vertical stanchions 150 that support the horizontal bumper rail 126. In the exemplary position shown, the bottom of ladder 5 is resting on top of horizontal bumper rail 126. If the user wants to maximize the height of the top step of ladder 5, he may block out the vertical slots in the roller tracks 37 (shown in FIG. 25), for example, by installing the plate 63 (shown in FIG. 25 and discussed in connection therewith). According to an exemplary embodiment, holes may be predrilled into roller tracks 37 and plate 63 to facilitate mounting of plate 63, if desired. As discussed above, if the vertical slots in roller tracks 37 are blocked, it may be necessary to remove a portion of channel iron 56 as shown to provide clearance for ladder 5 when raised enough to allow for the pin on slide bolt 67 to clear the top of horizontal bumper rail 126 when it is put back in storage position.
On the right side of FIG. 26, ladder 5 is shown in the storage position and secured there by an S-hook or similar mechanism extending between the ladder's bottom step and the trailer framing 59 and/or roller track 37. One of ordinary skill in the art will know that other structures can be implemented to hold ladder 5 in the storage position. The ladder 5 may be mounted in any of the three positions shown in FIG. 26 depending on which position is most advantageous to the user.
FIG. 27 shows an exemplary three-step version of ladder 5 attached to an open tailgate. The ladder 5 is shown in solid lines in the user-ready position, and in hidden lines in the storage position inside the truck bed. When in the user-ready position, the user support railings 16 can be left in the storage position at the side rails of ladder 5, or alternatively in the user-ready position. Ladder 5 can be mounted to the horizontal leg of angle iron 55 that is secured to the top side 4 of the tailgate, for example, by toggle bolts 21 or other fasteners extending through the top face 4 of the tailgate by one side of hinges 53. The other side of hinges 53 can be attached on the outside face of backdrop 61, for example, located behind and above the top step of ladder 5. One side of hinge 54 can be attached to the horizontal leg of angle iron 55 that is secured to the top side 4 of the tailgate, for example, by toggle bolts 21 or other fasteners extending through the top face 4 of the tailgate. The other side of hinge 54 can be attached to the outside vertical face of rectangular ladder holding plate 57. Rectangular ladder holding plate 57 can be adapted and configured such that when it is in the vertical position firmly against the outside vertical section of angle iron 55 (i.e., between the face 3 of the tailgate and the backdrop 61 of ladder 5), ladder will be held firmly in its user-ready position. When the tailgate is in the vertical or closed position, ladder 5 can be located in the storage position inside the bed of the vehicle. According to one exemplary embodiment, ladder holding plate 57 can be secured to the backdrop 61 of ladder 5, for example, by screws, bolts, or other fasteners extending through backdrop 61 and plate 57.
FIG. 28 is an isometric view of the ladder 5 of FIG. 27. Ladder 5 is shown in the user-ready position supported by backdrop 61. Backdrop 61 can be located behind and above the top step of ladder 5, for example, formed integrally with ladder 5 bracing or connected thereto. Backdrop 61 can rest firmly against rectangular ladder holding plate 57 when in the user-ready position. Ladder holding plate 57 is shown in the vertical position against the outside vertical face of angle iron 55, which is mounted against the outside face 3 of the tailgate. One side of each set of hinges 53 and 54 can be attached to the topside of the horizontal leg of angle iron 55, which in turn is secured to the top surface 4 of the tailgate, for example, by toggle bolts 21 or other fasteners. The other side of each of hinges 53 can be secured to the outside surface of backdrop 61 of ladder 5. Alternatively, the other side of hinges 54 can be secured to the outside surface of the rectangular holding plate 57 that is firmly against vertical leg of angle iron 55 when tailgate is in the open position.
FIG. 29 depicts a side view of another exemplary embodiment of a five step ladder similar to that shown in FIG. 25 and described in connection therewith. Ladder 5 is shown in both the user-ready position and the storage position. Compared to the ladder of FIG. 25, the ladder 5 of FIG. 29 includes the first ladder bracket 39, but not the second ladder bracket 52. In addition, the roller track 37 of FIG. 29 does not include the optional vertical slot of FIG. 25. In addition, as shown in the inset portion of FIG. 29, one or more additional rollers 27 may be provided in series behind each set of lead rollers 27. The lead rollers 27 may be coupled to the additional rollers 27, for example, by a metal strip riveted in place. The additional rollers 27 may ease the transition of ladder 5 from the open user-ready position to the storage position or visa versa.
FIG. 30 is a side view and FIG. 31 is a top view of an exemplary five step version of ladder 5 having an actuator mechanism to move ladder 5 from the storage position to the user-ready position, and vice versa. The actuator can comprise a pneumatic cylinder 65 having one end (e.g., the piston end) attached to the backdrop 61 of ladder 5. The other end of cylinder 65 can be secured to the tractor framing 59. Cylinder 65 can be located between the two sets of roller rails 37, as shown in FIG. 31, however other locations are possible.
When the piston of cylinder 65 is in an extended position (e.g., fully extended), the ladder 5 will be located in the user-ready position. Retracting the cylinder piston can return the ladder 5 to the storage position. When ladder 5 is returned to the storage position, its bottom step can rest on a horizontal plate 67 that is mounted to the bumper rail 26. The upper surface of plate 67 can be located at substantially the same elevation as the upper horizontal surface of bumper rail 26, as shown. Preferably, plate 67 is wide and long enough to engage and retain the bottom step of ladder 5, in order to hold ladder 5 in the storage position. Pneumatic cylinder 65 can be powered by compressed air provided by the vehicle. Alternatively, cylinder 65 may be a hydraulic cylinder. According to another exemplary embodiment, instead of a cylinder, the actuator mechanism can comprise a motor driven chain and sprocket system, a screw mechanism, or other linear actuator device known in the art.
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should instead be defined only in accordance with the following claims and their equivalents.

Claims

1. An apparatus, comprising:

a non-collapsible single unit stair comprising: a pair of opposing side rails supporting at least a top step and a bottom step; and

a roller system adapted to attach said apparatus adjacent to a substantially horizontal surface, said roller system providing for movement of the apparatus between a user-ready position and a storage position under said substantially horizontal surface.

2. The apparatus of claim 1, further comprising a height adjustable user-support arm, coupled to one of said side rails with a rotatable coupling, wherein said user-support arm is moveable between a support position and a storage position.

3. The apparatus of claim 2, further comprising a second height adjustable user-support arm.

4. The apparatus of claim 2, wherein said roller system comprises:

a pair of spaced-apart travel rails attached to said horizontal surface; and

a pair of rollers attached to said single unit stair and located on said travel rails.

5. The apparatus of claim 1, wherein said roller system is adapted to connect to the underside of a vehicle.

6. The apparatus of claim 1, further comprising an actuator mechanism adapted to move said apparatus between the user-ready position and the storage position.

7. The apparatus of claim 6, wherein said actuator mechanism comprises a pneumatic cylinder.

8. The apparatus of claim 1, further comprising an adjustable bracket associated with said single unit stair, said adjustable bracket adapted to connect to a structure associated with the substantially horizontal surface, wherein said adjustable bracket retains said single unit stair in the user-ready position.

9. The apparatus of claim 8, wherein said adjustable bracket is adapted to adjust at least the vertical height of said single unit stair with respect to the substantially horizontal surface when said single unit stair is in the user-ready position.

10. The apparatus of claim 8, further comprising at least one ladder brace connecting said adjustable bracket to said single unit stair.

11. An apparatus, comprising:

a non-collapsible single unit stair comprising: a pair of opposing side rails supporting at least a top step and a bottom step;

at least one hinge adapted to connect said apparatus to an edge of a horizontal surface, said hinge providing for movement of said single unit stair between a user-ready position and a storage position; and

a height adjustable user-support arm, coupled to one of said side rails with a rotatable coupling, wherein said user-support arm is moveable between a support position and a storage position.

12. The apparatus of claim 11, further comprising a second height adjustable user-support arm.

13. The apparatus of claim 11, further comprising an angle iron adapted to mount to said edge of said horizontal surface, wherein said hinge is mounted on said angle iron.

14. The apparatus of claim 13, further comprising a ladder holding plate, and at least one second hinge attaching said ladder holding plate to said angle iron.

15. The apparatus of claim 11, wherein said horizontal surface is part of a vehicle.

16. An apparatus, comprising:

a non-collapsible single unit stair comprising: a pair of opposing side rails supporting at least a top step and a bottom step, and a backdrop located behind and above the top step of the stair;

an angle iron adapted to mount to an edge of said horizontal surface, said angle iron comprising a first leg extending substantially parallel to the horizontal surface, and a second leg extending substantially perpendicular to the horizontal surface;

a ladder holding plate;

at least one first hinge connecting said single unit stair to said angle iron; and

at least one second hinge connecting said ladder holding plate to said angle iron;

wherein surface engagement between said angle iron and backdrop supports said single unit stair in said user-ready position.