CROSS REFERENCES TO CO-PENDING APPLICATIONS
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention -
The field of this invention is for safety as a hazardous barrier protection as
well as a fall protection device.
2. Description of the Prior Art -
Prior art systems made the user secure the device with some type of
securing method like anchor bolts or welding pieces together.
One similar piece of art to this invention is that it is a
cast base and uses rail sections. This system uses two
receiver posts in the base to support only two rail sections.
In the posts are four cast holes spaced 90 degrees from one
another. These holes are used to secure the rail sections to
the base with some type of securing pin.
Prior art has toe board receiver slots cast into the
perimeter of the base itself creating protrusions as compared
to this invention's adapters. This protrusion could extend up
to six inches from the base surface. By utilizing the adapter
method, you remove the potential hazard of the protrusion from
the base. One hazard is a potential tip-over of a forklift
driving over the protrusion. It will also protect human
injury by removing an accidental fall should someone trip over
the protrusion. These protrusions also become a nuisance when
toe boards are not in use.
No known system allows the infinite positioning, the
locking gates, and the removable toe board adaptors where the
present invention provides for all three qualities inclusive
or independent.
SUMMARY OF THE INVENTION
The general purpose of the present invention is
intended to be used to cordon off work areas and the like
where human safety is an issue. When the cast iron base is
coupled to the rail and/or gate sections, it has enough
weight, mass and strength to withstand tipping, thus the
system provides a safe means of protection should one fall
against it. It also meets and exceeds OSHA regulations for
permanent safety railings. When used on an elevated work
surface, optional toe board adapters are added. These
adapters enable the system to be in accordance with OSHA
regulations pertaining to elevated work areas.
The base is the integral component of this invention
and enables the system to be as versatile as it is described
herein. The base has four receiver posts so as to accommodate
as many as four rail sections, latching posts or gate posts,
to be incorporated at any one time. Thus, the system has the
versatility to have up to four quadrants of work areas to be
defined by the base placement. The base also incorporates
four symmetrically positioned holes to enable a permanent
mount to a surface, via some form of anchor bolts, if desired.
Designed into each of the receiver posts are
strategically positioned slots. These slots will align with
two vertically spaced holes in the vertical upright of the
rail section. This alignment will enable the rail sections to
be secured to the base at infinite positions along a 360°
rotation with some type of locking pin.
The rail sections used in this invention come in
varying lengths and are comprised of iron tubing with a
sufficient wall thickness to withstand the potential force
that could be exerted when a person falls against the rail
section. It is understood that aluminum or another
appropriate material may be used in the rail section
construction. The rail sections include a rail-locking system
that adds additional strength to the entire system preventing
tipping. The vertical uprights of each rail section have
doughnut-shaped metal pieces (securing rings) welded at equal
heights from the bottom of the upright. The securing rings
have precise internal cutouts that enable each rail section to
be secured to each other with some type of securing method.
A carabiner or locking safety chain would be sufficient to
additionally secure the rails together. The internal cutouts
enable the rail sections to be secured to one another at
infinite directions of any rail section that is incorporated
in the base at any one time.
This invention incorporates a derivative of the rail
section. It is a gate system that is utilized to access a
work area without having to remove locking pins and a rail
section to gain access. A coupler is designed to attach and
lock a gate post to the base receiver post. This feature is
important so it can lock the angle of assembly of the gate to
the base. Without the coupler, the gate would move within the
receiver post slots and not align with the gate latch post
after moving from its original installation position.
When this invention is used on an elevated work
surface, as defined by OSHA Regulations, an attachment for
required toe boards is available. Toe boards are intended to
keep objects from being kicked over the elevated work surface
that may cause injury to someone below. These toe board
adapters slide onto the lower ends of the vertical uprights of
each rail section and then are lowered on the toe board.
After positioning onto the toe board, the adapters are secured
to the rail section with a securing bolt or knob of one's
choice. The boards are then secured to the adapter by nails
or by a locking pin that is similar to or the same that secure
the rail section to the base. Because these adapters are
designed to rotate on the upright before being locked into
place, they can be positioned in any direction so that they
follow the in-line path of the rail section itself.
This invention comes with an optional number of
horizontal cross members or vertical uprights that can be
welded to the rail sections. This feature enables this
portable system to be used in a variety of markets. One
example of this feature is the agricultural market. One could
specify the requirements of spacing between the
horizontal/vertical spacing of the cross members so animals
could not escape from a livestock pen created using this
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects of the present invention and many of
the attendant advantages of the present invention will be
readily appreciated as the same becomes better understood by
reference to the following detailed description when
considered in connection with the accompanying drawings, in
which like reference numerals designate like parts throughout
the figures thereof and wherein:
FIG. 1 illustrates a perspective view of a safety
rail system, the present invention; FIG. 2 illustrates a top view of a base; FIG. 3 illustrates a side view of base; FIG. 4 illustrates a front view of two rail sections
connected together using rail lock donuts and a securing
chain; FIG. 5 illustrates a front view of a gate section
in conjunction with a latching post and a gate post; FIG. 6 illustrates a front view of a gate post and
rail section serving as a gate where locking coupler secures
gate post to receiver post of a base; FIG. 7 illustrates a cross sectional view of the
locking coupler; FIG. 8 illustrates a top view of a rail lock donut; FIG. 9 illustrates a front view of a rail section
supported by two bases incorporating a toe board secured in
place by toe board receivers; FIG. 10 illustrates a front view of a toe board
receiver; FIG. 11 illustrates a side view of a toe board
receiver; FIG. 12 illustrates a perspective view of the safety
rail system 10 configured for use in a manufacturing facility; FIG. 13 illustrates a perspective view of the safety
rail system constructed around a construction dig site; and, FIG. 14 illustrates a perspective view of a base and
rail section depicting how each receiver post has a 360°
rotation capacity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a perspective view of a safety
rail system 10, the present invention. This illustration
shows the safety rail system 10 assembled on a rooftop in a
random configuration. The safety rail system 10 is comprised
of a plurality of rail sections 12a-12n, a plurality of
bases 14a-14n, a plurality of rail lock donuts 16a-16n, a
plurality of securing chains 18a-18n, a plurality of toe
boards 20a-20n used in conjunction with a plurality of toe
board receivers 22a-22n. Each component will be later
described in detail with reference to the following figures.
FIG. 2 illustrates a top view of a base 14a, and
FIG. 3 illustrates a side view of base 14a, where all numerals
correspond to those elements previously described. The
bases 14a-14n weigh between 100-120 lbs. and are cast iron or
welded plate and tube to support rail sections 12a-12n without
tipping. Each base 14a-14n is constructed in the same manner
having identical parts including a planar portion 42 with
cutouts 40a-40d on four opposing sides creating built in
handles for transporting them. There is also a centrally
located lifting bar 46 which allows the user to hook the
bases 14a-14n to a pulley or a dolly to more easily move the
heavy bases 14a-14n. There are provided holes 38a-38d which
accommodate anchor bolts for securing the bases 14a-14n to a
work surface such as a concrete floor or roof top if permanent
or desired. The key feature of the bases 14a-14n are four
post receivers 36a-36d which extend perpendicularly upward
from planar portion 42. Rail sections 12a-12n are positioned
in the post receivers 36a-36n allowing the rail
sections 12a-12n to be positioned in any position in a 360°
range. These post receivers 36a-36d each include a plurality
of slots 44a-44n and the rail sections 12a-12n also
incorporate a plurality of corresponding holes 48a-48n, as
shown in FIG. 4, for receiving locking pins to hold the rail
sections 12a-12n in place in the bases 14a-14n once the
desired position is acquired. Once the rail sections 12a-12n
are secured to bases 14a-14n at each end, the slots will allow
the rail sections 12a-12n to pivot. Each base 14a-14n may
accommodate a maximum of four rail sections 12a-12n which can
be locked in any position within its range of motion. It is
understood that the slots 44a-44n may be substituted with
multiple holes at different heights, but holes will not allow
the infinite 360° range at which the rail sections 12a-12n may
be locked. The post receivers 36a-36d can also accommodate a
latching post 28 and/or a gate post 34 which will be described
in FIGS. 4 and 5.
FIG. 4 illustrates a front view of two rail
sections 12a-12n connected together using rail lock
donuts 16a-16n and a securing chain 18a, and FIG. 5
illustrates a front view of a gate section 32a in conjunction
with a latching post 28a and a gate post 34a, where all
numerals correspond to those elements previously described.
A plurality of latching posts 28a-28n and a plurality of gate
posts 34a-34n may be used in any configuration. Illustrated
in these figures are the holes 48a-48n which were mentioned in
the previous figures. The latching post 28 and the gate
post 34 also incorporate holes 48a-48n identical to those in
the rail sections 12a-12n and serve the same purpose. Also
illustrated are hinges 50a-50n which are secured to the gate
post 34 in at least two positions. The opposite ends of
hinges 50a-50n secure to the upright 26b of gate section 32a,
creating a pivoting gate. The gate section 32a also has a
gate latch 52 secured on the upright 26a of rail section 12a
opposite hinges 50a-50n. The gate latch 52 provides a locking
means for the gate section 32a. In the configuration
illustrated in FIG. 5, only the gate post 34a and the latching
post 28a are secured to bases 14a-14n (not illustrated) and
gate section 32a is suspended between them, creating the
operational gate. Both the latching post 28a and the gate
post 34a are locked in position using a locking coupler 54
which will be described in FIG. 6 and FIG. 7. It is necessary
to lock the gate post 34a in position using the locking
coupler 54 to prevent pivoting, keeping hinges 50a-50n in
position.
FIG. 6 illustrates a front view of a gate post 34a
and gate section 32a where locking coupler 54 secures gate
post 34a to receiver post 36a of base 14a, and FIG. 7
illustrates a cross sectional view of locking coupler 54,
where all numerals correspond to those elements previously
described. Illustrated in particular is the configuration of
the safety rail system 10 components when a gate is needed and
the locking coupler 54 is used. Also illustrated are a set of
holes 56a and 56b which lock the gate post 34a to the locking
coupler 54 and a hole 58 which allows the locking coupler 54
to be secured to receiver post 36a of base 14a by a securing
knob, bolt or other suitable device.
FIG. 8 illustrates a top view of a rail lock
donut 16a, where all numerals correspond to those elements
previously described. Illustrated in particular is a hole 60
where the rail lock donut 16a is secured to upright
portion 26b of rail section 12a and slots 62a-62b which
accommodate securing chains 18a-18n, as illustrated in FIGS. 4
and 5.
FIG. 9 illustrates a front view of a rail
section 12a supported by two bases 14a-14n incorporating a toe
board 20a secured in place by toe board receivers 22a-22n,
where all numerals correspond to those elements previously
described. With further reference to FIG. 10 and FIG. 11, the
use of the toe board will now be described in detail.
FIG. 10 illustrates a front view of a toe board
receiver 22a, and FIG. 11 illustrates a side view of a toe
board receiver 22a, where all numerals correspond to those
elements previously described. Each toe board
receiver 22a-22n includes a sleeve 64 which is slid upwardly
over and about the bottom of upright portion 26a of rail
section 12a prior to securing rail section 12a to base 14a.
Each sleeve 64 has a nut 74 welded to the outside over a hole,
not illustrated, in the sleeve 64, where an L-bolt 76 or the
like is screwed through the sleeve 64 and frictionally engages
upright portion 26a. The sleeve 64 may also be bolted or
welded, if necessary or so desired. There is a board receiver
bracket 66 connected at an angle to the sleeve 64 by shaft 68.
The board receiver bracket 66 is straddled over toe board 20a
and appropriately secured through holes 70a and 70b by a bolt,
securing pin or other appropriate means. Each rail
section 12a-12n should include two toe board receivers 22a-22n
and one toe board 20 as illustrated to prevent materials from
being kicked off an elevated work area using the safety rail
system 10.
FIG. 12 illustrates a perspective view of the safety
rail system 10 configured for use in a manufacturing facility,
where all numerals correspond to those elements previously
described. It defines the use for the four receiver
posts 36a-36d that are incorporated into the bases 14a-14n.
Unlimited work areas can be defined with this set up or one
similar to it. Also illustrated is how the gates 32a-32n are
used in conjunction with the rail sections 12a-12n. These
gate sections 32a-32n allow access to the work areas by
workers or a forklift for example. When the gate
sections 32a-32n are not in use, they are closed. When
closed, these gate sections 32a-32n create a safe barrier just
as the solid rail sections 12a-12n would. This illustration
shows work areas configured in squares, but it is understood
that the safety rail system 10 can be configured in any shape
needed.
FIG. 13 illustrates a perspective view of the safety
rail system 10 constructed around a construction dig site 78,
where all numerals correspond to those elements previously
described. This configuration allows the safety rail
system 10 to follow the various angles that are created by the
edge of the dig site 78 and still be secured in position by
the locking pins at any of the angles shown, as well as an
infinite number of angles not shown.
FIG. 14 illustrates a perspective view of a base 14a
and rail section 12a depicting how each receiver post 36a-36d
has the capability to be secured by a securing pin to a rail
section 12a-12d in a 360° rotator when utilizing the
slots 44a-44n in the receiver posts 36a-36d. A plurality of
holes at different horizontal planes may be substituted for
the plurality of slots 44a-44n, but the holes would limit the
direction the rail sections 12a-12n could be positioned and
not allow the infinite positioning that slots 44a-44n provide.
MODE OF OPERATION
With reference to FIGS. 1-14, the mode of operation
is now described, where all numerals correspond to those
elements previously described. The portable safety rail
system 10 is comprised of a number of components. The rail
sections 12a-12n come in varying lengths. Secured to the
upright portions 26a-26b of a rail section 12a is a rail-lock
donut 16a-16n. These rail lock donuts 16a-16n are secured at
equal heights on all rail sections 12a-12n by welding or other
appropriate means. When the rail sections 12a-12n are secured
in position and the rail lock donuts 16a-16n are coupled with
a securing chain 18a-18n, added strength is given to the
system should a rail section 12a-12n start to tip over. A
carabiner or other suitable device may be substituted for the
securing chains 18a-18n. The tipped over rail section 12a-12n
would then try to drag the next attached rail section 12a-12n
with it and so on. The overall weight will prevent the safety
rail system from tipping over. The rail lock donut 16a-16n is
designed so it too can accommodate the infinite directions
available to the rail sections 12a-12n as they are turned in
the receiver posts 36a-36d of bases 14a-14n.
The gate sections 32a-32n for the safety rail
system 10 are unique in design. A gate section 32a is
comprised of four major components. The latching post 28 is
where a gate latch 52 will secure the gate section 32a so to
not swing to and fro. The gate section 32a connects via
hinges 52a-52n to the gate post 34a. The gate
sections 32a-32n also have the capability to have infinite
positions for placement and when the desired direction is
found, the locking coupler 54 can easily lock the gate
sections 32a-32n into position so it will not move. The
locking coupler 54 is made of a lightweight metal such as
aluminum. It is machined half way through to be the outside
diameter of a rail section 12a-12n. The locking coupler 54
has holes 56a-56b for a securation means such as a spring pin
or bolt that can be installed on the rail section 12a-12n so
the rail section 12a-12n can not be removed. The lower
interior of the locking coupler 54 is machined tapered to fit
the tapered receiver post 36a-36d, or if tubing is used, it
would not need to be tapered. It also has a hole 58 so a knob
can be screwed into the hole and against the receiver post so
the rail section 12a-12n will not rotate when mounted into
position.
Although this invention was designed for
manufacturing facilities, construction sites and animal pens,
it can be used on an elevated work surfaces and meets or
exceeds OSHA's regulations for fall protection on an elevated
work surface. This invention has optional toe board
receivers 22a-22n which are slid over and about the bottoms of
each of the upright portions 26a-26b on rail sections 12a-12n.
A toe board 20a-20n, that meets OSHA'S standards, can be
secured to the board receiver bracket 66 and secured with a
screw, bolt or locking pin. Once in place, the toe board
receiver 22a-22n can be secured to the rail section by
tightening the L-Bolt 76 against the receiver posts 36a-36d of
bases 14a-14n. This device was also designed to have infinite
directional movement before securation. No matter what
position the base 14a-14n is when the rail section 12a-12n is
installed and secured, the toe board receivers 22a-22n will
always be able to follow the run of the rail sections 12a-12n.
The bases 14a-14n are of a cast iron design or
welded design to meet the weight requirements. They have
enough weight that when varying lengths of rail
sections 12a-12n or gate sections 32a-32n are secured to the
receiver posts 36a-36d, the safety rail system 10 can
withstand a minimum of 250 pounds of pressure from any angle.
This feature allows the system to be in compliance with OSHA's
Fall Protection Regulations. The bases 14a-14n each have four
receiver posts 36a-36d which allow the bases 14a-14n to
accommodate as many rail sections 12a-12n thus, creating a
maximum of four quadrants emanating from each base 14a-14n.
The receiver posts 36a-36d have strategically positioned
slots 44a-44n that enable the rail section 12a-12n to be
positioned in infinite directions while setting up another
base 14a-14n at the end of the rail section 12a-12n. When the
rail section 12a-12n is placed into the desired position,
bolts or locking pins are installed through the slot 44a-44n,
into the holes 48a-48n on the upright portions 26a-26b of rail
sections 12a-12n. One type of locking pin is a clevis pin
with a hole at one end for a lynch pin with a ball detent. A
double ring with a lanyard can connect between a top of the
clevis pin and the lynch pin for operator convenience. This
secures the rail sections 12a-12n in place.
Various modifications can be made to the present
invention without departing from the apparent scope hereof.
IT IS CLAIMED:
SAFETY RAIL SYSTEM |
PARTS LIST |
|
10 | safety rail system | 52 | gate latch |
12a-n | rail sections | | 54 | locking coupler |
14a-n | bases | | 56a-n | holes | |
16a-n | rail lock donuts | 58 | hole |
18a-n | securing chains | | 60 | hole |
20a-n | toe boards | | 62a-b | slots | |
22a-n | toe board receivers | 64 | sleeve |
26a-b | upright portions | 66 | board receiver bracket |
28a-n | latching posts | 68 | shaft |
32a-n | gate sections | | 70a-b | holes | |
34a-n | gate posts | 74 | nut |
36a-d | receiver posts | 76 | L-bolt |
38a-d | holes | 78 | dig site |
40a-d | cutouts | |
42 | planar portion |
44a-n | slots | |
46 | lifting bar |
48a-n | holes |
52a-n | hinges |