Ladder and stair

Abstract

The invention provides a ladder and a step. For example, the ladder may be a folding ladder having cantilevered steps that are disposed at one or more locations on a longitudinal bar assembly, such as a front longitudinal bar assembly. In one illustrative configuration, the cantilevered step may include a first or fixed portion disposed between a first longitudinal bar and a second longitudinal bar of the longitudinal bar assembly. The cantilevered step may also include a second or extension portion suspended from the first portion and extending beyond the first longitudinal bar and the second longitudinal bar. The second or extended portion of the cantilevered step may be coupled to the first or fixed portion along at least two discrete attachment surfaces.

Description

Technical Field

[0001] The present disclosure generally relates to ladders, and more particularly, to rungs for ladders. Background Art

[0002] Ladders generally provide access to elevated locations and / or items and can be used in a variety of positions. Depending on the position and / or the typical operating conditions of those positions, one or more features or accessories may be utilized with or built into the ladder to improve stability and / or usability. For example, it may be useful to provide features or accessories, for instance, to enhance the comfort and / or stability of a user who may work on a ladder for an extended period of time. Summary of the Invention

[0003] In one embodiment, there is provided a ladder comprising: a longitudinal bar assembly including a first longitudinal bar and a second longitudinal bar spaced apart from and opposite to the first longitudinal bar. A cantilever rung is coupled to the first longitudinal bar and the second longitudinal bar. The cantilever rung includes: a first portion disposed between the first longitudinal bar and the second longitudinal bar, and a second portion. The first portion includes a first wall, a second wall, and a third wall. The first wall forms at least a part of a standing surface, and the second wall and the third wall hang down from the first wall. The second portion is coupled to the first portion along the third wall at a first attachment surface and a second attachment surface. The second portion is suspended from the first portion such that the second portion extends beyond the longitudinal bar assembly.

[0004] In a second embodiment, there is provided a ladder comprising: a front longitudinal bar assembly and a rear longitudinal bar assembly. The front longitudinal bar assembly includes a first front longitudinal bar and a second front longitudinal bar spaced apart from and opposite to the first front longitudinal bar. The rear longitudinal bar assembly is coupled to the front longitudinal bar assembly at a hinge portion, the rear longitudinal bar assembly having a first rear longitudinal bar and a second rear longitudinal bar spaced apart from and opposite to the first rear longitudinal bar. A cantilever rung is coupled to the front longitudinal bar assembly, the cantilever rung including: a first portion and a second portion. The first portion is disposed between the first front longitudinal bar and the second front longitudinal bar, the first portion including a first wall, a second wall, and a third wall, the first wall forming at least a part of a standing surface, and the second wall and the third wall hang down from the first wall. The second portion is coupled to the first portion at a first attachment surface disposed on the third wall. The second portion is suspended from the first attachment surface such that the second portion extends beyond the first front longitudinal bar and the second front longitudinal bar.

[0005] In a third embodiment, a step is provided, the step including: a first portion and a second portion. The first portion includes a first wall, a second wall, a third wall, and a fourth wall, the first wall forming a standing surface, the second wall and the third wall hanging down from the first wall, and the fourth wall being opposite the first wall and extending between the second wall and the third wall. In some embodiments, the fourth wall includes a channel formed therein, the channel being disposed adjacent to the third wall. The second portion is coupled to the first portion, the second portion including a cantilever wall and an angled side edge. The cantilever wall is suspended from a first attachment surface on the third wall. The angled side edge hangs down from a distal end of the cantilever wall and extends inwardly toward the third wall at an acute angle relative to the cantilever wall, the angled side edge intersecting the third wall at a second attachment surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Various needs are at least partially met by providing a ladder having a cantilever step as described in the following detailed description, particularly when studied in conjunction with the drawings.

[0007] Figure 1 Front top perspective view of a ladder including a ladder having a cantilever step according to a first embodiment;

[0008] Figure 2 including Figure 1 right side view of a ladder;

[0009] Figure 3A including Figure 1 front top perspective view of a ladder in a closed position;

[0010] Figure 3B including Figure 1 rear top perspective view of a ladder in a closed position;

[0011] Figure 4 including Figure 1 right side view of a ladder in a closed position;

[0012] Figure 5 including Figure 1 perspective view of a portion of;

[0013] Figure 6 including Figure 1 top plan view of a portion of a ladder including a cantilever step;

[0014] Figure 7 including Figure 1 right end view of a portion of a ladder including a cantilever step and an end cap;

[0015] Figure 8 including Figure 1Right end view of a part;

[0016] Figure 9 Right end view of a cantilevered rung for a ladder according to the second embodiment;

[0017] Figure 10 Right end view of a cantilevered rung for a ladder according to the third embodiment;

[0018] Figure 11 Right end view of a cantilevered rung for a ladder according to the fourth embodiment;

[0019] Figure 12 Right end view of a cantilevered rung for a ladder according to the fifth embodiment;

[0020] Figure 13 Right end view of a cantilevered rung for a ladder according to the sixth embodiment;

[0021] Figure 14 Right end view of a cantilevered rung for a ladder according to the seventh embodiment; and

[0022] Figure 15 Right end view of a cantilevered rung for a ladder according to the eighth embodiment.

[0023] The elements in the figures are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions and / or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to aid in improving the understanding of the various embodiments of the present teachings. Additionally, commonly known elements that are useful or necessary in a commercially viable embodiment are typically not depicted in order to facilitate a more intuitive understanding of these various embodiments of the present teachings. Certain acts and / or steps may be described or depicted in a particular order of occurrence, and those skilled in the art will understand that such particularity of sequence is not actually required. Detailed Description

[0024] The present disclosure provides a ladder or other similar structure that includes one or more cantilevered steps. For example, the ladder can be a folding ladder having cantilevered steps disposed at one or more locations on a longitudinal bar assembly, such as on a front longitudinal bar assembly. In one illustrative method, the cantilevered step includes: a first or fixed portion disposed between a first longitudinal bar and a second longitudinal bar of the longitudinal bar assembly; and a second or extending portion that is suspended from the first portion and extends beyond the first longitudinal bar and the second longitudinal bar and toward a rear longitudinal bar assembly. The second or extending portion of the cantilevered step can be coupled to the first or fixed portion along at least two discrete attachment surfaces. In this manner, in one illustrative embodiment, the cantilevered portion is supported by the fixed portion and does not directly contact the longitudinal bar assembly. The second or extending portion of the cantilevered step increases the area of the standing surface and can help, particularly when a user is on the ladder for an extended period of time, enhance the user's comfort and stability.

[0025] The first or fixed portion of the cantilevered step can include a bottom wall that is opposite the standing surface of the first or fixed portion. Additionally, the second portion (or a portion thereof) can have a wall thickness that is greater than the wall thickness of the first portion (or a portion thereof). These features can help limit the vertical displacement of the second or extending portion of the cantilevered step when the cantilevered step is subjected to a load, thereby strengthening the interface. Additionally, limiting the vertical displacement can enhance the user's perception of stability.

[0026] The second or extending portion of the cantilevered step can also include an angled side edge disposed at a distal end of the cantilevered step. The angled side edge can be disposed at an acute angle relative to the standing surface of the cantilevered step. In this manner, the angled side edge can prevent the cantilevered step from interfering with a step or a horizontal bar or other features disposed on the rear longitudinal bar assembly of the ladder.

[0027] The second or extending portion of the cantilevered step can also be shorter than the first or fixed portion. In some configurations, the end of the second or extending portion of the cantilevered step can be tapered such that the proximal end of the extending portion is longer than the distal end of the extending portion. In this manner, the cantilevered step can avoid coupling to other ladder components or attachments (e.g., a spreader, for example) coupled to the longitudinal bar. In this manner, the cantilevered or deeper steps described herein can have multiple lengths and, in some configurations, multiple widths.

[0028] The cantilevered steps described herein can be integrated into any type of ladder, including step ladders, ceiling ladders, extension ladders, multi-position ladders, etc. The cantilevered steps described herein can also be incorporated into other pole structures, e.g., pole assemblies having two or more vertical components (e.g., poles, tubes, etc.) joined together by at least one horizontal component (e.g., steps, rungs, tubes, etc.). The other pole structures include, but are not limited to, scaffolding and work platforms.

[0029] In some aspects, a ladder includes a pole assembly that includes a first pole and a second pole spaced apart from and opposite the first pole. The ladder further includes a cantilevered step coupled to the first pole and the second pole. The cantilevered step includes a fixed or first portion disposed between the first pole and the second pole. The first portion of the cantilevered step includes a first wall, a second wall, and a third wall. The first wall forms at least a portion of a standing surface. The second wall and the third wall depend from the first wall. The cantilevered step further includes an extension or second portion coupled to the first portion along the third wall at a first attachment surface and a second attachment surface. The second portion is suspended from the first portion such that the second portion extends beyond the pole assembly.

[0030] In some aspects, a ladder includes a front pole assembly that includes a first front pole and a second front pole spaced apart from and opposite the first front pole. The ladder further includes a rear pole assembly coupled to the front pole assembly at a hinge portion. The rear pole assembly has a first rear pole and a second rear pole spaced apart from and opposite the first rear pole. The ladder further includes a cantilevered step coupled to the front pole assembly. The cantilevered step includes a fixed or first portion disposed between the first front pole and the second front pole. The first portion includes a first wall, a second wall, and a third wall. The first wall forms at least a portion of a standing surface. The second wall and the third wall depend from the first wall. The cantilevered step further includes an extension or second portion coupled to the first portion at a first attachment surface disposed on the third wall. The second portion is suspended from the first attachment surface such that the second portion extends beyond the first front pole and the second front pole.

[0031] In some aspects, a rung for a ladder includes a fixed or first portion that includes a first wall, a second wall, a third wall, and a fourth wall. The first wall forms a standing surface. The second wall and the third wall depend from the first wall. The fourth wall is opposite the first wall and extends between the second wall and the third wall. The fourth wall includes a channel formed therein. The channel is disposed adjacent to the third wall. The cantilevered rung further includes an extension or second portion coupled to the first portion. The second portion includes a cantilevered wall and an angled side edge. The cantilevered wall is suspended from a first attachment surface on the third wall. The angled side edge depends from a distal end of the cantilevered wall and extends inwardly toward the third wall at an acute angle relative to the cantilevered wall. The angled side edge intersects the third wall at a second attachment surface.

[0032] The terms and expressions used herein have the ordinary technical meaning given to such terms and expressions by those skilled in the art as set forth above, unless a different specific meaning has been set forth herein. Unless otherwise expressly indicated, when used herein, the word "or" shall be interpreted to have a disjunctive construction rather than a conjunctive construction. Unless otherwise specified herein, the terms "coupled," "fixed," "attached to," etc. refer to both direct coupling, fixing, or attaching and indirect coupling, fixing, or attaching through one or more intermediate components or features.

[0033] Unless the context clearly indicates otherwise, the singular forms "a / an" and "the" include plural references.

[0034] As used throughout the specification and claims herein, approximate language is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as "about," "approximately," and "substantially" is not limited to the precise value specified. In at least some instances, the approximate language may correspond to the precision of the instrument used for measuring the value, or the precision of the method or machine used for constructing or manufacturing the component and / or system. For example, the approximate language may refer to within a 10% margin.

[0035] Now referring to the drawings, and specifically to Figures 1 to 8 , a ladder 100 including a cantilevered rung 102 is shown. The cantilevered rung extends or is suspended beyond the side rails of the ladder 100. The cantilevered rung 102 can provide an extended standing surface to provide comfort for a user of the ladder 100.

[0036] Although the ladder 100 is depicted as having two cantilevered rungs 102, it is contemplated that one or more, and in some methods even all, of the rungs of the ladder 100 may be cantilevered rungs. In some configurations, the ladder 100 includes at least one cantilevered rung 102 in the working area of the ladder 100 where a user may stand for an extended period of time. For example, at least one cantilevered rung 102 may be disposed at a height between about 1 foot and about 6 feet or between about 1 foot and about 5 feet, as measured from the ground to the top of the cantilevered rung when the ladder 100 is in the open position.

[0037] As shown, the ladder 100 is a folding ladder having a front longitudinal member assembly 104 and a rear longitudinal member assembly 106. The front longitudinal member assembly 104 is coupled to the rear longitudinal member assembly 106 at an articulated portion 105. The front longitudinal member assembly 104 includes a first front longitudinal member 108 spaced apart from and opposite a second front longitudinal member 110. The first front longitudinal member 108 is parallel to the second front longitudinal member 110. The front longitudinal member assembly 104 further includes a plurality of rungs or steps 114 disposed between the first front longitudinal member 108 and the second front longitudinal member 110. The rungs 114 may be standard rungs, i.e., rungs having a consistent length and width, which are confined within the coverage area of the first front longitudinal member 108 and the second front longitudinal member 110 and do not have portions that overhang beyond the first front longitudinal member 108 and the second front longitudinal member 110. The rear longitudinal member assembly 106 includes a first rear longitudinal member 116 spaced apart from and opposite a second rear longitudinal member 118. The first rear longitudinal member 116 is parallel to the second rear longitudinal member 118. The rear longitudinal member assembly 106 includes a plurality of horizontal bars 120 disposed between the first rear longitudinal member 116 and the second rear longitudinal member 118. The cantilevered rung 102 is disposed in the front longitudinal member assembly 104.

[0038] In one illustrative configuration, the first front longitudinal member 108, the second front longitudinal member 110, the first rear longitudinal member 116, and the second rear longitudinal member 118 are C-shaped. In some configurations, the first front longitudinal member 108 includes a first front inner flange 108A spaced apart from a first front outer flange 108B by a first front web 108C. The first front inner flange 108A, the first front outer flange 108B, and the first front web 108C form a first front channel 109 extending along the first front longitudinal member 108. The second front longitudinal member 110 includes a second front inner flange 110A spaced apart from a second front outer flange 110B by a second front web 110C. The second front inner flange 110A, the second front outer flange 110B, and the second front web 110C form a second front channel 111 (not shown) extending along the second front longitudinal member 110. Similarly, the first rear longitudinal member 116 may include a first rear inner flange 116A spaced apart from a first front outer flange 116B by a first rear web 116C. The second rear longitudinal member 118 generally also includes a second rear inner flange 118A spaced apart from a second rear outer flange 118B by a first rear web 118C.

[0039] However, the vertical bars of the ladder 100 can be of any suitable shape. For example, in some configurations, the vertical bars of the ladder 100 can be circular with a generally circular cross-section, D-shaped with a flat side and a curved side that rests against the ladder rungs or steps, square or rectangular, I-beam-shaped with a cross-sectional shape generally similar to the letter "I", or box-shaped with a square or rectangular cross-sectional shape with a hollow interior.

[0040] Now turning to Figures 5 to 8 , the cantilevered rung 102 of the ladder 100 is shown in detail. The cantilevered rung 102 includes a first portion 126 and a second portion 128.

[0041] The first portion 126 of the cantilevered rung 102 is disposed between the first front vertical bar 108 and the second front vertical bar 110. The first portion 126 has a length L1 (see Figure 6 ). Once installed, the length L1 can be the distance between the first front web 108C of the first front vertical bar 108 and the second front web 110C of the second front vertical bar 110. The first portion 126 has a first end 126A and a second end 126B disposed opposite the first end 126A. The first end 126A is received or nested within the first front channel 109 of the first front vertical bar 108. The second end is received or nested within the second front channel 111 of the second front vertical bar 110.

[0042] The first portion 126 includes a first surface, segment or wall 130, a second surface, segment or wall 132, a third surface, segment or wall 134, and a fourth surface, segment or wall 136. The first wall 130 can form at least a part of the standing surface of the cantilevered rung 102. The second wall 132 and the third wall 134 hang down from the first wall 130 and can thus be the side walls of the first portion 126. The fourth wall 136 is disposed opposite and spaced apart from the first wall 130 and extends between the second wall 132 and the third wall 134. The fourth wall 136 can be the bottom wall of the first portion 126.

[0043] The first wall 130 may include a tread surface to enhance grip or provide slip resistance. In some methods, the entire standing surface of the first wall 130 or the cantilevered step 102 may have the same tread pattern as the step 114. In some instances, the first wall 130 includes a plurality of pips 131. As used herein, a "pip" refers to a protrusion or ridge that extends laterally across at least a portion of the step (e.g., along length L1 or L2 or in the extrusion direction of the step). In some methods, the pips 131 may be arranged in pip groupings between about 2 pips to about 10 pips, about 2 pips to about 8 pips, or about 2 pips to about 4 pips. In other configurations, other configurations of protrusions or ridges may be employed, such as, for example, discrete circular protrusions, cross-hatching, and / or any other pattern of interest.

[0044] The second wall 132 may be coupled to the first front longitudinal bar 108 and to the second front longitudinal bar 110. For example, the second wall 132 may be attached to the first front longitudinal bar 108 and the second front longitudinal bar 110 via any suitable attachment mechanism (e.g., via fasteners (e.g., rivets), welding, forging, or bonding). In some instances, the second wall 132 may include one or more openings that receive fasteners to attach the cantilevered step 102 to the first front inner flange 108A of the first front longitudinal bar 108 and to the second front inner flange 110A of the second front longitudinal bar 110.

[0045] The third wall 134 may be coupled to the first front longitudinal bar 108 and to the second front longitudinal bar 110. The third wall 134 may be attached to the first front longitudinal bar 108 and the second front longitudinal bar 110 via any suitable attachment mechanism (e.g., via fasteners (e.g., rivets), welding, or bonding). In some instances, the third wall 134 may include one or more openings that receive fasteners to attach the cantilevered step 102 to the first front inner flange 108A of the first front longitudinal bar 108 and to the second front inner flange 110A of the second front longitudinal bar 110.

[0046] The fourth wall 136 may include a notch or a channel 140 formed therein. By one method, the channel 140 is positioned adjacent to the third wall 134. The channel 140 may be defined by a first channel wall 142, a second channel wall 144, and at least a portion of the third wall 134. The first channel wall 142 is disposed opposite the third wall 134 of the first portion 126. In an illustrative method, the second channel wall 144 extends between the first channel wall 142 and the third wall 134 of the first portion. The second channel wall 144 is generally inclined or disposed at an angle with respect to the first wall 130 of the first portion 136. In some configurations, the second channel wall 144 is disposed at an angle between about 90 degrees and about 150 degrees, about 100 degrees and about 140 degrees, or about 110 degrees and about 130 degrees with respect to the third wall 134. In some embodiments, the fourth wall 136 may not include the channel 140 (see, e.g., Figure 9 ).

[0047] In some instances, the first portion 126 of the cantilevered step 102 may have a width W1-A between about 2 inches and about 6 inches, between about 2 inches and about 5 inches, between about 2.5 inches and about 4.5 inches, or between about 3 inches and about 4 inches. In some instances, one or more walls of the first portion 126 may have a wall thickness between about 0.02 inches and about 0.10 inches, between about 0.03 inches and about 0.08 inches, between about 0.03 inches and about 0.07 inches, or between about 0.035 inches and about 0.055 inches. In still other instances, the third wall 134 (e.g., the wall shared between the first portion 126 and the second portion 128) may be thicker than one or more of the first wall 130, the second wall 132, and the fourth wall 136 of the first portion 126. It is contemplated that increasing the wall thickness of the third wall 134 may help reduce the maximum deflection of the cantilevered step 102. For example, the third wall 134 may have a wall thickness between about 0.03 inches and about 0.14 inches, between about 0.04 inches and about 0.12 inches, between about 0.05 inches and about 0.10 inches, or between about 0.06 inches and about 0.09 inches.

[0048] The first portion 126 may have a cross-sectional profile that is generally C-shaped, D-shaped, and / or box-shaped, etc. For example, when the cross-sectional profile of the first portion 126 is generally C-shaped, the first portion 126 may lack the fourth wall 136. In some instances, the first portion 126 may have the same cross-sectional profile as the step 114. In other instances, the first portion 126 may have a cross-sectional profile different from that of the step 114.

[0049] In some embodiments, the ladder 100 may include a ladder top that is or includes one or more rubber buffers coupled thereto such that the ladder 100 can lean firmly against another structure, such as a wall, column, corner, wall post, etc. The cantilever rung 102 may also include a locking mechanism on the horizontal bar 120 that is received by the channel 140. In operation, the locking mechanism may slide downward along the second portion 128 and then rest in the channel 140 to fix the front longitudinal bar assembly 104 to the rear longitudinal bar assembly 106, for example, such that the ladder can lean firmly against another structure.

[0050] The second portion 128 of the cantilever rung 102 is suspended from the first portion 126. In this way, the second portion 128 extends beyond the first front longitudinal bar 108 and the second front longitudinal bar 110 toward the rear longitudinal bar assembly 106 (see, for example Figure 2 ). The second portion 128 of the cantilever rung 102 has a length L2 (see Figures 6 to 7 ). In some methods, the length L2 of the second portion 128 of the cantilever rung 102 is shorter than the length L1 of the first portion 126 of the cantilever rung 102. Thus, the cantilever rung 102 may have at least two different lengths along different portions of its width W.

[0051] The second portion 128 includes a cantilever wall 129 and an extension or angled edge 148 that hangs down from the cantilever wall 129. As discussed below, the extension or angled edge may include several angles, segments, surfaces, or portions thereof. Additionally, the cantilever wall 129 generally extends from the first portion 126 along a first attachment point, line, or surface 150. The cantilever wall 129 may form at least a portion of the standing surface on the cantilever rung 102. Like the second wall 132, the cantilever wall 129 may also include a tread surface and one or more protrusions to enhance grip.

[0052] By one method, the angled edge 148 extends toward the third wall 134 and joins the third wall at a second point, line, or attachment surface 152. The angled edge 148 forms an opening in the second portion 128, which can help the cantilever rung 102 avoid the horizontal bar 120 disposed in the rear longitudinal bar assembly 106. In some instances, the angled edge 148 or a portion or segment thereof may be disposed at an angle between about 10 degrees and about 60 degrees, between about 10 degrees and about 50 degrees, between about 10 degrees and about 30 degrees, between about 15 degrees and about 25 degrees, between about 35 degrees and about 55 degrees, between about 40 degrees and about 50 degrees with respect to the cantilever wall 129. In some instances, at least a portion or segment of the angled edge 148 may be disposed approximately parallel to the cantilever wall 129 or at an angle less than 10 degrees.

[0053] In some instances, the angled side edge 148 may include at least two discrete segments. In a first embodiment, the angled side edge 148 includes a first segment 148a, a second segment 148b, and a third segment 148c. In one instance, the first side edge 148a may be disposed at an angle between about 10 degrees and about 40 degrees, between about 10 degrees and about 30 degrees, or between about 15 degrees and about 25 degrees relative to the cantilever wall 129. In one instance, the first side edge 148a may be disposed at an angle between about 20 degrees and about 60 degrees, between about 35 degrees and about 55 degrees, between about 40 degrees and about 50 degrees relative to the cantilever wall 129. In one instance, the first segment 148c may be disposed substantially parallel to the cantilever wall 129 or at an angle less than 10 degrees.

[0054] The second portion 128 is coupled to the first portion 126 at two attachment lines or surfaces 150, 152. The first attachment surface 150 includes the intersection of the cantilever wall 129 and the third wall 134 of the first portion 126. The second attachment surface 152 includes the intersection of the angled side edge 148 and the third wall 134 of the first portion 126. In some configurations, when the cantilever step 102 is installed in the ladder 100, the first portion 126 does not contact the first front rail 108 or the second front rail 110. Thus, the second portion 128 may be supported only by the first portion 126 and the interfaces of the first portion 126 with the first front rail 108 and the second front rail 110.

[0055] The second portion 128 has a proximal portion 128A and a distal portion 128B. The proximal portion 128A is adjacent to the first portion 126 of the cantilever step 102. The distal portion 128B of the proximal portion 128A is opposite the proximal portion 128A. In some configurations, the length L2 of the second portion 128 may decrease in the direction extending from the proximal portion 128A to the distal portion 128B.

[0056] The second portion 128 has a first end 128C and a second end 128D. In some configurations, the first end 128C and the second end 128D are tapered or angled relative to the transverse direction X of the cantilever step 102 (see Figure 6 ). The decreasing length L2 of the second portion 128 results in the tapering of the first end 128C and the second end 128D. In some instances, the first end 128C and the second end 128D may be disposed at an angle between about 1 degree and about 30 degrees, between about 5 degrees and about 20 degrees, or between about 5 degrees and about 15 degrees relative to the transverse direction X of the cantilever step 102. Angling the second portion 128 in this manner can assist the cantilever step 102 in clearing the braces 122A, 122B as the ladder moves between the open and closed positions.

[0057] In some instances, the second portion 128 may have a width W1-B that is between about 1 inch and about 6 inches, between about 1 inch and about 5 inches, between about 1 inch and about 4 inches, between about 1 inch and about 3 inches, or in some aspects may be about 2 inches (see, for example Figure 7 ).

[0058] In some configurations, the second portion 128 or a portion thereof may have a wall thickness that is greater than the wall thickness of the first portion 126. For example, one or more of the cantilevered wall 129 and the angled side edge 148 of the second portion 128 may have a wall thickness that is greater than the wall thickness of one or more of the first wall 130, the second wall 132, or the fourth wall 136 of the first portion 126. Additionally, in some configurations, the wall thickness of the third wall 134 may be greater than the wall thickness of the cantilevered wall 129 and the angled side edge 148. In some instances, one or more walls of the second portion 128 (e.g., the cantilevered wall 129 or the angled side edge 148) may have a wall thickness that is between about 0.04 inches and about 0.10 inches, between about 0.05 inches and about 0.09 inches, between about 0.05 inches and about 0.09 inches, or between about 0.06 inches and about 0.08 inches.

[0059] In some instances, the cantilevered rung 102 may have a maximum deflection that is between about 0.01 inches and about 0.20 inches, between about 0.03 inches and about 0.18 inches, between about 0.05 inches and about 0.15 inches, or between about 0.08 inches and about 0.12 inches. The maximum deflection within the above ranges may provide a perception of stability to a user of the ladder 100. As used herein, the maximum deflection may refer to the vertical displacement of the second portion 128 of the cantilevered rung 102 when a load is applied to the cantilevered rung 102. The load used to determine the maximum deflection is twice the load rating of the ladder, with a safety factor of 10%. In one non-limiting example, if the load rating of the ladder is 300 pounds, then the load used to determine the maximum deflection will be 660 pounds.

[0060] In some configurations, the cantilevered rung 102 may include end caps 154. By one method, the end caps 154 are inserted into the first end 128C and the second end 128D. In some instances, the end caps 154 may be attached to the first end 128C and the second end 128D via one or more fasteners (e.g., rivets). In other instances, the end caps 154 may be fixed in place via a friction fit connection. It is contemplated that any suitable attachment mechanism may be used to secure the end caps 154 to the second portion 128 of the cantilevered rung 102.

[0061] In some methods, the cantilevered rung 102 can be formed as a one-piece extrusion such that the first portion 126 and the second portion 128 are formed as a single piece with a fixed cross-sectional profile along its length. In other methods, the first portion 126 and the second portion 128 can be formed as two separate pieces that are coupled together, for example, via a friction fit connection, fasteners, bonding, or other means. In such methods, the first portion 126 can be a one-piece extrusion, and the second portion 128 can be a separate one-piece extrusion. In Figure 10 and 11 illustrates an example of a two-piece cantilevered rung.

[0062] Now returning to Figures 1 to 4 , the ladder 100 includes two cantilevered rungs 102. The lower cantilevered rung can be shorter than the upper cantilevered rung. For example, the length of the lower rung (e.g., L1) can be greater than the length of the upper rung (e.g., L1). In some examples, the length of the lower cantilevered rung (e.g., L1) can be between about 13 inches and about 21 inches or between about 15 inches and about 19 inches. In some examples, the length of the upper cantilevered rung (e.g., L1) can be between about 10 inches and about 20 inches or between about 13 and about 17 inches. As Figure 1 shown, the lower cantilevered rung can have an exposed length E1 between about 12 inches and about 20 inches, between about 12 inches and about 18 inches, between about 14 inches and about 18 inches, or between about 16.5 inches and about 17.5 inches. The upper cantilevered rung can have an exposed length E2 between about 9 inches and about 19 inches, between about 11 inches and about 17 inches, between about 12 inches and about 16 inches, or between about 13 inches and about 15 inches.

[0063] The ladder 100 further includes braces 122A, 122B that are coupled to the front longitudinal bar assembly 104 and the rear longitudinal bar assembly 106. The first brace 122A is coupled to the first front longitudinal bar 108 and the first rear longitudinal bar 116 and can include one or more hinges or pivot points that allow the first brace 122A to fold and unfold. The second brace 122B is coupled to the second front longitudinal bar 110 and the second rear longitudinal bar 118 and can include one or more hinges or pivot points that allow the second brace 122B to fold and unfold. For example, when a force is applied to the front longitudinal bar assembly 104 and / or the rear longitudinal bar assembly 106 to expand or fold the ladder 100, the braces 122 can fold or unfold.

[0064] The ladder 100 may be collapsible such that the front longitudinal member assembly 104 and the rear longitudinal member assembly 106 may be extended or collapsed via the hinge portion 105, for example, for storage or transportation. Thus, the ladder 100 may assume a first open position in which the front longitudinal member assembly 104 is spaced apart or extended from the rear longitudinal member assembly 106. The ladder 100 may also assume a second closed position in which the front longitudinal member assembly 104 is adjacent to or folded against the rear longitudinal member assembly 106.

[0065] In the open position, the braces 122A, 122B of the ladder 100 are deployed and fix the front longitudinal member assembly 104 relative to the rear longitudinal member assembly 106. Figures 1 to 2 The ladder shown in the open position.

[0066] In the closed position, the braces 122A, 122B are folded and allow the front longitudinal member assembly 104 to fold or move toward the rear longitudinal member assembly 106. FIGS. 3 to 4 show the ladder 100 in the closed position. When the ladder is in the closed position, the cantilevered rung 102 nests between the first brace 122A and the second brace 122B. In some configurations, the cantilevered rung 102 has a total rung width W1 (see Figure 8 ). The total rung width W extends between the second wall 132 and the distal portion 128B of the second portion 128. Additionally, in the closed position, the ladder 100 has a ladder width W2. The ladder width W2 extends from the front longitudinal member assembly 104 to the rear longitudinal member assembly 106, and specifically, from the first front flange 108B to the second front flange 110B. As Figure 4 shown, the total rung width W1 is less than the ladder width W2. Thus, the cantilevered rung 102 conforms to the profile of the ladder 100 in the closed position.

[0067] In some examples, the total rung width W may be between about 3 inches and about 12 inches, between about 3 inches and about 10 inches, between about 3 inches and about 8 inches, between about 3 inches and about 7 inches, between about 3.5 inches and about 8.5 inches, between about 4 inches and about 8 inches, between about 4 inches and about 6 inches, or in some aspects may be about 5 inches.

[0068] Figure 9 The cantilevered rung 202 according to a second embodiment is shown. In the second embodiment, the cantilevered rung 202 has angled side edges 148 with an alternative shape. Additionally, the first portion 226 of the cantilevered rung 202 lacks a notch or channel (e.g., channel 140) in the bottom wall. Elements in the second embodiment that are similar to elements in the first embodiment have been given similar reference numerals in the 200 series, and only the general differences will be discussed below. For example, the cantilevered rung 102 described in the first embodiment is numbered as the cantilevered rung 202 in the second embodiment.

[0069] The first portion 226 of the cantilevered step 202 includes a first wall 230, a second wall 232, a third wall 234, and a fourth wall 236. In the first portion 226 of the cantilevered step 202, the fourth wall 236 does not include a channel formed therein. Rather, the fourth wall 236 is generally straight from the second wall 232 to the third wall 234. In this way, the first portion 226 has a generally box-shaped cross-sectional profile.

[0070] The second portion 228 of the cantilevered step 202 includes a first cantilevered wall 229, a side edge 260, an angled side edge 248, and a second cantilevered wall 262. The cantilevered wall 229 is suspended from the third wall 234 at a first attachment surface 250. In some methods, the tread surface of the cantilevered wall 229 includes a tread surface different from that of the cantilevered wall 129 in the first embodiment. For example, the tread surface on the cantilevered wall 229 includes a first protrusion group 264 including two protrusions, a second protrusion group 266 including four protrusions, and a third protrusion group 268 including two protrusions. The tread pattern on the cantilevered wall 229 is the same as the tread pattern on the first wall 230 of the first portion 226. The side edge 260 hangs down from the cantilevered wall 229 at the distal end 228B of the second portion 228. The side edge 260 can be generally parallel to the third wall 234 and the second wall 232 of the first portion 226. The angled side edge 248 extends inward from the side edge 260 toward the second cantilevered wall 262. The second cantilevered wall 262 is suspended from the third wall 234 at a second attachment surface 252.

[0071] In some methods, the cantilevered step 202 can have a maximum displacement between about 0.02 inches and about 0.08 inches, between about 0.02 inches and about 0.06 inches, or between about 0.02 inches and about 0.05 inches.

[0072] Figure 10 A cantilevered step 302 according to a third embodiment is shown. In the third embodiment, the first portion 326 of the cantilevered step 302 is reduced. By one method, the first portion 326 lacks a fourth wall (e.g., the fourth wall 236). Additionally, the first portion 326 and the second portion 328 of the cantilevered step 302 are separate pieces that are coupled together, for example, via fasteners. Elements in the third embodiment similar to elements in the second embodiment have been given similar reference numerals in the 300 series, and only the general differences will be discussed below. For example, the cantilevered step 202 described in the second embodiment is numbered as the cantilevered step 302 in the third embodiment.

[0073] The first portion 326 of the cantilevered step 302 includes a first wall 330, a second wall 332, and a third wall 334. The first portion 236 does not include a fourth wall or a bottom wall. Thus, the cross-sectional profile of the first portion 326 is generally C-shaped.

[0074] The second portion 328 of the cantilevered step 302 includes a first cantilevered wall 329, a first side edge 360, an angled side edge 348, and a second cantilevered wall 362. The second portion 328 further includes a second side edge 370. The second side edge 370 hangs down from the first cantilevered wall 329 at the proximal end 328A of the cantilevered step 302. In some configurations, the second side edge 370 may be generally parallel to the first side edge 360. Additionally, the second cantilevered wall 362 may be generally parallel to the first cantilevered wall 329.

[0075] Although in the second embodiment, the third wall 234 is shared between the first portion 226 and the second portion 228, in the third embodiment, the second portion 328 includes a second side edge 370 that is coupled to the third wall 334 via a fastener (such as a rivet). It is contemplated that any suitable fastener may be used to couple the second side edge 370 of the second portion 328 to the third wall 334 of the first portion 326.

[0076] Furthermore, although in the second embodiment, the second portion 228 is coupled to or suspended from the first portion 226 at two discrete attachment surfaces 250, 252, in the third embodiment, the second portion 328 is coupled to the first portion 326 at a larger single surface (attachment surface 372). As Figure 10 shown, the interface between the third wall 344 and the second side edge 370 extends from adjacent the top to adjacent the bottom. The attachment surface 372 is the plane of the second side edge 370 that mates with the third wall 334 of the first portion 326. The attachment surface 372 and the third wall 334 may have corresponding openings (not shown) through which the fastener may be inserted to couple the third wall 334 to the second side edge 370.

[0077] In some methods, the cantilevered step 302 may have a maximum displacement between about 0.08 inches and about 0.20 inches, between about 0.10 inches and about 0.18 inches, or between about 0.12 inches and about 0.16 inches.

[0078] Figure 11Shows the cantilever step 402 according to the fourth embodiment. In the fourth embodiment, the cantilever step 402 includes a first portion 426 that lacks a bottom wall or a fourth wall. Additionally, in the cantilever step 402, the first portion 426 is coupled to the second portion 428 via a slot and a corresponding protrusion. Elements in the fourth embodiment similar to those in the third embodiment have been given similar reference numerals in the 400 series, and only the general differences will be discussed below. For example, the cantilever step 302 described in the third embodiment is numbered as the cantilever step 402 in the fourth embodiment.

[0079] The first portion 426 of the cantilever step 402 includes a first wall 430, a second wall 432, and a third wall 434. The first portion 436 does not include a fourth wall or a bottom wall. Thus, the cross-sectional profile of the first portion 426 is generally C-shaped. The third wall 434 includes a slot or groove 474 formed therein. In one example, the slot 474 can be a generally T-shaped slot (e.g., having a t-shaped cross-sectional profile). However, the slot 474 can be formed in any suitable geometry to mate with a portion of the second portion 428.

[0080] The second portion 428 of the cantilever step 402 includes a first cantilever wall 429, a first side edge 460, an angled side edge 448, and a second cantilever wall 462. The second portion 428 further includes a second side edge 470. The second side edge 470 hangs down from the first cantilever wall 429 at the proximal end 428A of the cantilever step 402. In some configurations, the second side edge 470 can be generally parallel to the first side edge 460. The second side edge 470 includes a protrusion 476. The protrusion 476 can have a geometry corresponding to the geometry of the slot 474 on the third wall 434. In one example, the protrusion 476 can be T-shaped, having a first arm 476A and a second arm 476B. The protrusion 476 engages the slot 474 along an attachment surface 472.

[0081] While in the third embodiment, the third wall 334 of the first portion 326 is coupled to the second side edge 370 of the second portion 428 via a fastener, in the fourth embodiment, the third wall 434 includes a slot 474, and the second side edge 470 includes a protrusion 476 that is received by the slot 474 to couple the first portion 426 to the second portion 428.

[0082] In some methods, the cantilever step 402 can have a maximum displacement between about 0.02 inches and about 0.14 inches, between about 0.04 inches and about 0.14 inches, or between about 0.06 inches and about 0.12 inches.

[0083] Figure 12Shows the cantilever step 502 according to the fifth embodiment. In the fifth embodiment, the second part 528 of the cantilever step 502 includes a cross brace 580, and the cross brace 580 is disposed in the hollow interior of the second part 528. Elements in the fifth embodiment similar to those in the first embodiment have been given similar reference numerals in the 500 series, and only the general differences will be discussed below. For example, the cantilever step 102 described in the first embodiment is numbered as the cantilever step 502 in the fifth embodiment.

[0084] The first part 526 of the cantilever step 502 includes a first wall 530, a second wall 532, a third wall 534, and a fourth wall 536. In the first part 526 of the cantilever step 502, the fourth wall 536 includes a channel 540 formed therein.

[0085] The second part 528 of the cantilever step 502 includes a cantilever wall 529 and an angled side edge 548. The cantilever wall 529 is suspended from the third wall 534 at a first attachment surface 550. The cantilever wall 529 includes a tread surface different from the tread surface of the cantilever wall 129 in the first embodiment. For example, the tread surface on the cantilever wall 529 includes a first protrusion group 564 including two protrusions, a second protrusion group 566 including four protrusions, and a third protrusion group 568 including two protrusions. The tread pattern on the cantilever wall 529 can be the same as the tread pattern on the first wall 530 of the first part 526. The angled side edge 548 extends toward the third wall 534 and joins the third wall at a second attachment surface 552.

[0086] The second part 528 further includes a pier or cross brace 580. The cross brace 580 is formed by a third cantilever wall 582 and ribs 584. The third cantilever wall 582 is suspended from the third wall 534 at a third attachment surface 586. In some configurations, the third cantilever wall 582 can extend generally parallel to the cantilever wall 529. The ribs 584 hang down from the cantilever wall 529. The ribs 584 are disposed between the proximal end 528A and the distal end 528B of the second part 528. In some configurations, the ribs 584 are disposed between the first protrusion group 564 and the second protrusion group 566 on the cantilever wall 529.

[0087] The cross brace 580 can help fix the end cap to the second part 528 of the cantilever step 502. For example, the cross brace can be coupled to the corresponding geometry on the end cap to provide a friction fit connection between the end cap and the cantilever step 502. The cross brace 580 can also reinforce the second part 528 against deflection.

[0088] In some methods, the cantilever step 502 can have a maximum displacement between about 0.01 inches and about 0.12 inches, between about 0.02 inches and about 0.1 inches, or between about 0.03 inches and about 0.07 inches.

[0089] Figure 13 Shows the cantilever step 602 according to the sixth embodiment. In the sixth embodiment, the second part 628 of the cantilever step 602 includes a pier or a cross brace. Elements in the sixth embodiment similar to those in the fifth embodiment have been given similar reference numerals in the 600 series, and only the general differences will be discussed below. For example, the cantilever step 502 described in the fifth embodiment is numbered as the cantilever step 602 in the sixth embodiment.

[0090] Similar to the sixth embodiment, the second part 528 of the cantilever step 502 includes a cross brace 680. However, while the cross brace 580 in the fifth embodiment includes two discrete segments (e.g., the third cantilever wall 582 and the rib 584), the cross brace 680 in the second embodiment is a single discrete segment. Additionally, the cross brace 680 intersects the third wall 634 at the second attachment surface 652. Thus, the second part 628 is coupled to the first part 626 only at two attachment surfaces (e.g., the first attachment surface 550 and the second attachment surface 552).

[0091] The first part 626 of the cantilever step 602 includes a first wall 630, a second wall 632, a third wall 634, and a fourth wall 636. In the first part 626 of the cantilever step 602, the fourth wall 636 includes a channel 640 formed therein.

[0092] The second part 628 of the cantilever step 602 includes a cantilever wall 629 and an angled side edge 648. The cantilever wall 629 is suspended from the third wall 634 at the first attachment surface 650. The angled side edge 648 extends inwardly toward the third wall 634 at an acute angle relative to the cantilever wall 629 and joins the third wall 634 at the second attachment surface 652.

[0093] The second part 628 further includes a cross brace 680. The cross brace 680 hangs down from the cantilever wall 629. The cross brace 680 extends across a hollow opening within the second part 628. The cross brace 680 has a first end 680A that is coupled to the cantilever wall 629 between the proximal end 628A and the distal end 628B of the second part 628. In some configurations, the first end 680A of the cross brace 680 is disposed between the first protrusion grouping 664 and the third protrusion grouping 668, and in some instances, may be adjacent to the second protrusion grouping 666. The cross brace 680 has a second end 680B that is coupled to or intersects the third wall 634 and the angled side edge 648 at or near the second attachment surface 652.

[0094] In some methods, the cantilevered step 602 can have a maximum displacement between about 0.01 inches and about 0.12 inches, between about 0.02 inches and about 0.1 inches, or between about 0.03 inches and about 0.07 inches.

[0095] Figure 14 Show a cantilevered step 702 according to a seventh embodiment. In the seventh embodiment, the second portion 728 of the cantilevered step 702 includes ribs 790 extending into a hollow opening within the second portion 728. Elements in the seventh embodiment similar to elements in the first embodiment have been given similar reference numerals in the 700 series, and only the general differences will be discussed below. For example, the cantilevered step 102 described in the first embodiment is numbered as the cantilevered step 702 in the seventh embodiment.

[0096] The first portion 726 of the cantilevered step 702 includes a first wall 730, a second wall 732, a third wall 734, and a fourth wall 736. In the first portion 726 of the cantilevered step 702, the fourth wall 736 includes a channel 740 formed therein.

[0097] The second portion 728 of the cantilevered step 702 includes a cantilever wall 729 and an angled edge 748. The cantilever wall 729 is suspended from the third wall 734 at a first attachment surface 750. The angled edge 748 extends inwardly toward the third wall 734 at an acute angle relative to the cantilever wall 729 and joins the third wall 734 at a second attachment surface 752.

[0098] The second portion 728 further includes ribs 790. The ribs 790 depend from the cantilever wall 729 and are disposed between a proximal portion 728A and a distal portion 728B of the second portion 728. The ribs 790 extend partially into a hollow opening within the second portion 728. By one method, the ribs 790 extend inwardly toward the third wall 734 at an acute angle relative to the cantilever wall 729. The ribs 790 can help secure an end cap to the second portion 728 of the cantilevered step 702. For example, the ribs 790 can be coupled to corresponding geometries on the end cap to provide a friction fit connection between the end cap and the cantilevered step 702. In some instances, the ribs 790 can have a length between about 0.01 inches and about 0.75 inches, between about 0.05 inches and about 0.60 inches, or between about 0.10 inches and about 0.50 inches.

[0099] In some methods, the cantilevered step 702 can have a maximum displacement between about 0.04 inches and about 0.16 inches, between about 0.06 inches and about 0.14 inches, or between about 0.08 inches and about 0.12 inches.

[0100] Figure 15Shows the cantilevered step 802 according to the eighth embodiment. In the eighth embodiment, the cantilevered step 802 includes a tread pattern different from that of the first embodiment, having different groupings of protrusions. In addition, the shape of the channel 840 in the first portion 826 of the cantilevered step 802 has a different shape from the channel 140 in the first embodiment. Elements in the eighth embodiment similar to those in the first embodiment have been given similar reference numerals in the 800 series, and only the general differences will be discussed below. For example, the cantilevered step 102 described in the first embodiment is numbered as the cantilevered step 802 in the eighth embodiment.

[0101] The first portion 826 of the cantilevered step 802 includes a first wall 830, a second wall 832, a third wall 834, and a fourth wall 836. In the first portion 826 of the cantilevered step 802, the fourth wall 836 includes a notch or channel 840 formed therein. The channel 840 is defined by a first channel wall 842, a second channel wall 844, and at least a portion of the third wall 834. The first channel wall 842 is disposed opposite the third wall 834 of the first portion 826. The second channel wall 844 extends between the first channel wall 842 and the third wall 834 of the first portion. In some configurations, the second channel wall 144 is disposed at an angle between about 80 degrees and about 130 degrees, about 90 degrees and about 120 degrees, or about 90 degrees and about 110 degrees relative to the third wall 134.

[0102] The first wall 830 of the first portion 826 includes a tread pattern on its upper surface, which has a first grouping of protrusions 892A and a second grouping of protrusions 892B. The first grouping of protrusions 892A may include between about 2 protrusions and about 10 protrusions, between about 4 protrusions and about 10 protrusions, or between about 4 protrusions and about 8 protrusions. The second grouping of protrusions 892B may include between about 2 protrusions and about 10 protrusions, between about 4 protrusions and about 10 protrusions, or between about 4 protrusions and about 8 protrusions. In some non-limiting examples, the number of protrusions in the first grouping of protrusions 892A may be the same as the number of protrusions in the second grouping of protrusions 892B.

[0103] The second portion 828 of the cantilevered step 802 includes a cantilever wall 829 and an angled side edge 848. The cantilever wall 829 is suspended from the third wall 834 at a first attachment surface 850. The angled side edge 848 extends inwardly toward the third wall 834 at an acute angle relative to the cantilever wall 829 and joins the third wall 834 at a second attachment surface 852.

[0104] The cantilever tread 829 includes a tread pattern on its upper surface, which has a first set of protrusions 894A and a second set of protrusions 894B. The first set of protrusions 894A can include between about 2 and about 10 protrusions, between about 4 and about 10 protrusions, or between about 4 and about 8 protrusions. The second set of protrusions 894B can include between about 2 and about 10 protrusions, between about 4 and about 10 protrusions, or between about 4 and about 8 protrusions. In some instances, the number of protrusions in the first set of protrusions 894A can be the same as the number of protrusions in the second set of protrusions 894B. In some instances, the set of protrusions on the first portion 826 is the same as the set of protrusions on the second portion 828.

[0105] In some methods, the cantilever step 802 can have a maximum displacement between about 0.01 inches and about 0.10 inches, between about 0.01 inches and about 0.08 inches, or between about 0.01 inches and about 0.06 inches.

[0106] It is contemplated that any of the features in the embodiments of the cantilever steps described and Figures 1 to 15 depicted herein can be combined in any manner. Any aspect of the various illustrated embodiments can be combined to form new combinations.

[0107] The ladders, components, and / or accessories described herein can be formed from a variety of materials and using a variety of manufacturing techniques. Such materials can include, for example, metals, plastics, and other polymers and / or composite materials. Additionally, some portions of the components of the ladder can be formed from one material, and one or more other components or accessories can be formed from another similar or completely different material. In some configurations, the side rails of the ladder can be formed from a composite material (such as fiberglass or fiberglass-reinforced plastic (FRP)) and manufactured via a pultrusion process. The FRP material can include various plastic resins (such as polyurethane or polyethylene), or can include various glass materials. It is contemplated that adjusting the FRP formulation to use different material combinations can reduce the material weight and / or cost. The side rails can also be formed from a metal material (such as aluminum or an aluminum alloy) and manufactured via an extrusion process. After extrusion or pultrusion, the ladder side rails are typically cut to a certain length. For box-shaped side rails, a computer numerical control (CNC) machine can machine or form one or more holes in the side rails. For other shaped side rails (such as C-shaped or I-beam-shaped side rails), other tools (such as a punch press) can be utilized to punch one or more holes in the side rails.

[0108] The rungs of the ladder can be made of composite materials (such as fiberglass or carbon fiber). In some methods, the rungs can also be made of metallic materials (such as magnesium, magnesium alloy, aluminum, or aluminum alloy). The rungs can be manufactured via an extrusion process and cut to a certain length. The rungs can have various shapes and can be, for example, circular, D-shaped, or triangular. Additionally, the rungs can have a hollow or substantially hollow cross-section.

[0109] The rungs of the ladder can be attached to the side rails in various different ways. In one method, the rungs and the side rails are forged together, for example, by attaching the rungs to the side rails via a direct type forging connection. In the direct type forging connection, the rungs are directly attached to the side rails using a cold forming process, where a moving die forms the rungs around a pre-punched hole in the side rails. An annealing operation can be used to soften the metal to prevent cracking. In other methods, in addition to other types of attachment, the rungs are also attached to the side rails via a rung plate connection. In the rung plate connection, the rungs are attached to a plate, and the plate is attached to the side rails via one or more rivets or other mechanical elements.

[0110] Other accessories and assemblies used in the ladder (such as feet, locks, ropes, rope pulleys, end caps, and / or gussets) can be made of materials such as rubber or plastic (such as polypropylene or any other suitable plastic). The plastic parts can be injection molded or insert molded. In some methods, the accessories and assemblies (such as guide brackets, feet, gussets, and / or locks) can be formed, extruded, or stamped from metallic materials (such as aluminum, aluminum alloy, or steel). The rubber feet can be riveted to the base of the ladder. The metal locks can be extruded and then cut to a certain length. The rope pulley can include an extruded metal side portion and a plastic circular pulley formed by injection molding plastic, where the side portion and the pulley are held together by rivets. The end caps can be riveted or snapped onto the ladder during assembly. Similarly, the knee pads can be riveted to the ladder.

[0111] Those skilled in the art will recognize that various other modifications, variations, and combinations can also be made to the embodiments described above without departing from the scope of the present invention, and such modifications, variations, and combinations should be considered within the scope of the inventive concept.

Claims

1. A ladder comprising: A longitudinal bar assembly comprising a first longitudinal bar and a second longitudinal bar spaced apart from and opposite to the first longitudinal bar; and a cantilevered step coupled to the first longitudinal bar and the second longitudinal bar, the cantilevered step comprising: a first portion disposed between the first longitudinal bar and the second longitudinal bar, the first portion comprising a first wall, a second wall and a third wall, the first wall forming at least a portion of a standing surface, the second wall and the third wall depending from the first wall; and A second portion is coupled to the first portion along the third wall at a first attachment surface and a second attachment surface, the second portion being suspended from the first portion such that the second portion extends beyond the longitudinal bar assembly.

2. The ladder of claim 1, wherein the cantilevered step has a maximum displacement of less than about 0.125 inches. 3 . The ladder of claim 1 , wherein the first portion has a cross-sectional shape of at least one of a C-shape or a box-shape.

4. The ladder of claim 1, wherein the second portion includes a cantilevered wall depending from the first attachment surface, wherein the cantilevered wall is coplanar with the first wall of the first portion.

5. The ladder of claim 4, wherein the second portion further includes a proximal portion adjacent to the first portion and a distal portion opposite the proximal portion, the distal portion including an angled side edge depending from the cantilevered wall and extending toward the third wall to join the third wall at the second attachment surface.

6. The ladder of claim 1, wherein the first portion further comprises a fourth wall disposed opposite the first wall and extending between the second wall and the third wall.

7. The ladder of claim 6, wherein the fourth wall includes a channel formed therein, the channel being disposed adjacent to the third wall of the first portion.

8. The ladder of claim 1, wherein the first portion and the second portion of the cantilevered step are hollow.

9. The ladder of claim 1, wherein the cantilevered rung further comprises at least one end cap secured to an open end of the cantilevered rung via a friction fit connection.

10. A ladder comprising: a front longitudinal bar assembly comprising a first front longitudinal bar and a second front longitudinal bar spaced apart from and opposite to the first front longitudinal bar; a rear longitudinal bar assembly coupled to the front longitudinal bar assembly at a hinge portion, the rear longitudinal bar assembly having a first rear longitudinal bar and a second rear longitudinal bar spaced apart from and opposite the first rear longitudinal bar; and a cantilevered step coupled to the front longitudinal bar assembly, the cantilevered step comprising: a first portion disposed between the first front longitudinal bar and the second front longitudinal bar, the first portion comprising a first wall, a second wall and a third wall, the first wall forming at least a portion of a standing surface, the second wall and the third wall depending from the first wall; and A second portion is coupled to the first portion at a first attachment surface disposed on the third wall, the second portion depending from the first attachment surface such that the second portion extends beyond the first front longitudinal bar and the second front longitudinal bar.

11. The ladder of claim 10, wherein the cantilevered rung is disposed at a first position on the front longitudinal bar assembly, wherein the rear longitudinal bar assembly further includes a horizontal bar extending between the first rear longitudinal bar and the second rear longitudinal bar at a second position on the rear longitudinal bar assembly, and wherein the second position is opposite the first position.

12. The ladder of claim 10, wherein the ladder further comprises a first strut and a second strut coupled to the front and rear longitudinal assemblies, and wherein the cantilevered rung is nested between the first strut and the second strut when the ladder is folded.

13. The ladder of claim 10, wherein the cantilevered rung has an overall rung width extending between the second wall and a distal edge of the second portion, wherein the ladder has a ladder width extending between the front and rear longitudinal bar assemblies, and wherein the overall rung width is less than the ladder width.

14. The ladder of claim 10, wherein the second portion further comprises an angled side edge depending from a distal end of the second portion and coupled to the third wall at a second attachment surface.

15. A ladder comprising: a first portion including a first wall, a second wall, a third wall and a fourth wall, wherein the first wall forms a standing surface, the second wall and the third wall depend from the first wall, and the fourth wall is opposite to the first wall and extends between the second wall and the third wall; and A second portion is coupled to the first portion, the second portion comprising a cantilevered wall and an angled side edge, the cantilevered wall depending from a first attachment surface on the third wall, the angled side edge depending from a distal end of the cantilevered wall and extending inwardly toward the third wall at an acute angle relative to the cantilevered wall, the angled side edge intersecting the third wall at a second attachment surface.

16. A step according to claim 15, wherein the fourth wall includes a channel formed therein, the channel being disposed adjacent to the third wall, wherein the channel is defined by at least a portion of the third wall of the first portion, a first channel wall, and a second channel wall, the first channel wall being disposed opposite the third wall of the first portion, and the second channel wall extending between the first channel wall and the third wall of the first portion.

17. The step of claim 16, wherein the second channel wall is disposed at an angle between about 90 degrees and about 150 degrees relative to the third wall.

18. The step of claim 15, wherein the second portion further comprises a rib coupled to the cantilevered wall, the rib extending into the hollow interior of the second portion.

19. The step of claim 15, wherein the second portion further comprises a cross brace coupled to the second portion, the cross brace extending from the cantilevered wall to the third wall of the second portion.

20. The step of claim 19, wherein the cross brace includes a second side edge depending from the cantilevered wall and a third cantilevered wall extending from the third wall of the second portion.

Images