Safety rail system

Abstract

 The invention relates to an improved portable safety guardrail system, which utilizes a cast iron base or a welded base and tubular guardrail sections and gates. The system is designed to meet and exceed OSHA Fall Protection Regulations while having the appeal of being modular and portable with no need for anchoring devises (i.e., anchor bolts, etc.). This invention allows for infinite configuration of a guardrail system to suit the needs of the user.

Description

CROSS REFERENCES TO CO-PENDING APPLICATIONS

[0001] None.

BACKGROUND OF THE INVENTION

1. Field of the Invention -

[0002] 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 -

[0003] 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.

[0004] 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.

[0005] 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

[0006] 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.

[0007] 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.

[0008] 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.

[0009] 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.

[0010] 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.

[0011] 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.

[0012] 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

[0013] 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

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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

Claims

1. A rail safety system including a base, the base comprising:

a. a plate;

b. at least one cutout;

c. at least one hole spaced from said cutout;

d. at least one lifting bar;

e. at least one receiver post for receiving a post with holes in a lower end; and,

f. a plurality of offset slots in said receiver post, whereby the slots receive a pin pushed through the slot and into the hole of said post.

2. The system of claim 1, including a post in said receiver post and a rail lock means on said post.

3. A rail safety system comprising:

a. a plate, at least one cutout, at least one hole spaced from said cutout, at least one lifting bar, a plurality of receiver posts for receiving a post with holes in a lower end, and a plurality of offset slots in said receiver post, whereby the slots receive a pin pushed through the slot and into the hole of said post; and,

b. at least one gate means engaged into said two receiver posts of said two plates.

4. A rail safety system comprising:

a. a plate, at least one cutout, at least one hole spaced from said cutout, at least one lifting bar, a plurality of receiver posts for receiving a post with holes in a lower end, and a plurality of offset slots in said receiver post, whereby the slots receive a pin pushed through the slot and into the hole of said post;

b. at least one gate means engaged into said two receiver posts of said two plates;

c. rail lock means on each end of said gate means; and,

d. at least one toe board means engaged between opposing ends of said gate means.

5. A rail safety system comprising:

a. a plate, at least one cutout, at least one hole spaced from said cutout, at least one lifting bar, a plurality of receiver posts for receiving a post with holes in a lower end, and a plurality of offset slots in said receiver post, whereby the slots receive a pin pushed through the slot and into the hole of said post;

b. at least one gate means engaged into said two receiver posts of said two plates;

c. rail lock means on each end of said gate means; and,

d. at least one toe board means engaged between opposing ends of said gate means.

Drawing