Scaffold plank with end connector and method of making the same

Abstract

A scaffold plank assembly for engagement to a scaffolding frame. The scaffold plank assembly comprises an elongate, non-metal plank which defines opposed first and second ends and at least one interior cavity. Attached to respective ones of the opposed ends of the plank is a pair of end connectors. The end connectors each comprise a main body, and at least two arms which are attached to the main body. Attached to and extending from the main body is at least one attachment finger which is extensible into the interior cavity of the plank. The main body also includes at least two notches formed therein which are sized and configured to receive respective ones of the arms of another end connector in a nesting fashion. Additionally, disposed within the attachment finger of the end connector is an aperture which may be coaxially aligned with a pair of apertures disposed within the plank when the attachment finger is fully advanced into the interior cavity thereof. These coaxially aligned apertures are adapted to receive an elongate pin which, when advanced through the apertures and secured to the plank, maintains the end connector in firm engagement to the plank. The plank itself may further be provided with a non-slip texture which is formed directly within the outer, top surface of the top wall thereof.

1 . A scaffold plank assembly for engagement to a scaffolding frame, the scaffold plank assembly comprising: 
 an elongate, non-metal plank defining opposed first and second ends; and    a pair of end connectors attached to respective ones of the opposed ends of the plank, each of the end connectors comprising: 
 a main body defining an arcuate body engagement surface;  
 an attachment portion which is integrally connected to the main body and cooperatively engageable the plank; and  
 at least two arms attached to the main body, each of the arms defining an arcuate arm engagement surface, the body and arm engagement surfaces being sized and configured to be cooperatively engageable to the scaffolding frame;  
 the main body including at least two notches formed therein which each have a shape that is complementary to the arms, at least one of the notches being disposed between the arms for matingly receiving one of the arms of a similar adjacent end connector therein; and  
   a pair of elongate pins, each of the pins being extensible through the attachment portion of a respective one of the end connectors and through a portion of the plank adjacent one of the first and second ends thereof.    
   
   
       2 . The scaffold plank assembly of  claim 1  wherein each of the end connectors is fabricated from a non-metal material.  
   
   
       3 . The scaffold plank assembly of  claim 2  wherein each of the end connectors further comprises an internal metallic reinforcement plate which extends at least partially within the main body and arms thereof.  
   
   
       4 . The scaffold plank assembly of  claim 1  wherein each of the end connectors further comprises at least one locking clip attached to the main body and frictionally engageable to the scaffolding frame.  
   
   
       5 . The scaffold plank assembly of  claim 1  wherein the arcuate arm engagement surfaces are substantially continuous with the body engagement surface in each of the end connectors.  
   
   
       6 . The scaffold plank assembly of  claim 1  wherein the attachment portion comprises at least one elongate attachment finger which is extensible into an interior cavity defined by the plank and includes an aperture disposed therein which is sized and configured to accommodate the advancement of a respective one of the pins therethrough.  
   
   
       7 . The scaffold plank assembly of  claim 6  wherein the attachment portion comprises a plurality of attachment fingers which extend in spaced, generally parallel relation to each other and are each extensible into the interior cavity of the plank, each of the attachment fingers including an aperture disposed therein, the apertures of the attachment fingers being generally coaxially aligned with each other and sized and configured to accommodate the advancement of a respective one of the pins therethrough.  
   
   
       8 . The scaffold plank assembly of  claim 7  wherein the plank is fabricated from a plastic material.  
   
   
       9 . The scaffold plank assembly of  claim 8  wherein the plank includes: 
 an elongate, generally planar top wall defining inner and outer surfaces and opposed pairs of longitudinal and lateral sides;    an elongate, generally planar bottom wall defining inner and outer surfaces and opposed pairs of longitudinal and lateral sides;    an opposed pair of sidewalls integrally connected to the top and bottom walls and extending along respective pairs of the longitudinal sides of the top and bottom walls in generally parallel relation to each other; and    a plurality of reinforcement walls integrally connected to and extending perpendicularly between the inner surfaces of the top and bottom walls and in spaced, generally parallel relation to each other and to the side walls;    the attachment fingers of each of the end connectors being extensible between respective adjacent pairs of the sidewalls and reinforcement walls of the plank.    
   
   
       10 . The scaffold plank assembly of  claim 9  wherein: 
 each of the sidewalls and reinforcement walls of the plank includes a spaced pair apertures disposed therein, the apertures of the sidewalls and reinforcement walls being segregated into two generally coaxially aligned sets which are disposed in relative close proximity to respective ones of the opposed first and second ends of the plank;    the apertures of each set are coaxially alignable with the apertures of the attachment fingers of respective ones of the end connectors when the attachment fingers of each of the end connectors are extended between respective adjacent pairs of the sidewalls and reinforcement walls of the plank; and    the coaxially aligned apertures of the plank and each of the end connectors are sized and configured to accommodate the advancement of a respective one of the pins therethrough.    
   
   
       11 . The scaffold plank assembly of  claim 9  wherein at least the outer surface of the top wall includes a textured pattern integrally formed therein.  
   
   
       12 . An end connector for attachment to an elongate plank defining opposed first and second ends, the end connector being engageable to a scaffolding frame and comprising: 
 a main body defining an arcuate body engagement surface;    a plurality of attachment fingers which are integrally connected to the main body and extend in spaced, generally parallel relation to each other, each of the attachment fingers being extensible into an interior cavity of the plank and including an aperture disposed therein, the apertures of the attachment fingers being generally coaxially aligned with each other; and    at least two arms attached to the main body, each of the arms defining an arcuate arm engagement surface, the body and arm engagement surfaces being sized and configured to be cooperatively engageable to the scaffolding frame;    the main body including at least two notches formed therein which each have a shape that is complementary to the arms, at least one of the notches being disposed between the arms for matingly receiving one of the arms of a similar adjacent end connector therein.    
   
   
       13 . The end connector of  claim 12  wherein the end connector is fabricated from a non-metal material.  
   
   
       14 . The end connector of  claim 13  wherein the end connector further comprises an internal metallic reinforcement plate which extends at least partially within the main body and arms thereof.  
   
   
       15 . The end connector of  claim 12  wherein the end connector further comprises at least one locking clip attached to the main body and frictionally engageable to the scaffolding frame.  
   
   
       16 . The end connector of  claim 12  wherein the arcuate arm engagement surfaces are substantially continuous with the body engagement surface.  
   
   
       17 . A scaffold plank assembly for engagement to a scaffolding frame, the scaffold plank assembly comprising: 
 an elongate, non-metal plank defining opposed first and second ends;    a pair of end connectors attached to respective ones of the opposed ends of the plank, each of the end connectors comprising: 
 a main body defining an arcuate body engagement surface;  
 at least two attachment fingers which are integrally connected to the main body and extend in spaced, generally parallel relation to each other, each of the attachment fingers being extensible into an interior cavity of the plank and including an aperture disposed therein, the apertures of the attachment fingers being generally coaxially aligned with each other; and  
 at least two arms attached to the main body, each of the arms defining an arcuate arm engagement surface which is substantially continuous with the body engagement surface, the body and arm engagement surfaces being sized and configured to be cooperatively engageable to the scaffolding frame;  
 the main body including at least two notches formed therein which each have a shape that is complementary to the arms, at least one of the notches being disposed between the arms for matingly receiving one of the arms of a similar adjacent end connector therein; and  
   a pair of elongate pins, each of the pins being extensible through the coaxially aligned apertures of a respective one of the end connectors and through a portion of the plank adjacent one of the first and second ends thereof.    
   
   
       18 . The scaffold plank assembly of  claim 17  wherein the plank includes: 
 an elongate, generally planar top wall defining inner and outer surfaces and opposed pairs of longitudinal and lateral sides;    an elongate, generally planar bottom wall defining inner and outer surfaces and opposed pairs of longitudinal and lateral sides;    an opposed pair of sidewalls integrally connected to the top and bottom walls and extending along respective pairs of the longitudinal sides of the top and bottom walls in generally parallel relation to each other; and    a plurality of reinforcement walls integrally connected to and extending perpendicularly between the inner surfaces of the top and bottom walls and in spaced, generally parallel relation to each other and to the side walls;    the attachment fingers of each of the end connectors being extensible between respective adjacent pairs of the sidewalls and reinforcement walls of the plank.    
   
   
       19 . The scaffold plank assembly of  claim 18  wherein: 
 each of the sidewalls and reinforcement walls of the plank includes a spaced pair apertures disposed therein, the apertures of the sidewalls and reinforcement walls being segregated into two generally coaxially aligned sets which are disposed in relative close proximity to respective ones of the opposed first and second ends of the plank;    the apertures of each set are coaxially alignable with the apertures of the attachment fingers of respective ones of the end connectors when the attachment fingers of each of the end connectors are extended between respective adjacent pairs of the sidewalls and reinforcement walls of the plank; and    the coaxially aligned apertures of the plank and each of the end connectors are sized and configured to accommodate the advancement of a respective one of the pins therethrough.    
   
   
       20 . The scaffold plank assembly of  claim 17  wherein at least the outer surface of the top wall includes a textured pattern integrally formed therein.