Components to allow buckets to be used as structural or alternative elements

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COMPONENTS TO ALLOW BUCKETS TO BE USED AS STRUCTURAL OR ALTERNATIVE ELEMENTS

RELATED APPLICATION (0001] This application is being filed on 30 September 2010, as a PCT

International Patent application in the name of Primordial Soup, LLC, a U.S. national corporation, applicant fpr the designation of all countries except the U.S., and Tim Bachman, a citizen of the U.S., Matthew Vail Leyden, a citizen of the U.S., Christian Richard Trifilio, a citizen of the U.S., Jeff Waffensmith, a citizen of the

U.S,, and Rod St. Michel, a citizen of the U.S,, applicants for the designation of the

U.S. only, and claims priority to U.S. Patent Application Serial No. 61/247,337 filed on 30 September 2009.

BACKGROUND

[0002] The five-gallon bucket is a common item at construction sites, garages, and in the backs of pickup trucks all over the country. Originally intended to ship bulk quantities of food for the foodservice industry or bulk quantities of speckling etc. for the construction industry, people have found that there are several additional uses for the buckets. Such uses include using them to hold paint to use with a roller to holding bait for fishing, The result is that these buckets are readily available at home improvement stores to purchase as well as there being a large volume of buckets in the field that have been re-purposed and are being re-used after their initial use has expired.

[0003] The five-gallon bucket, although thin and rpade of plastic, is a relatively strong component that can easily support a 200 plus pound man sitting on top of it, In addition, the buckets are light-weight, stackable, and stpre easily.

SUMMARY

[0004] The disclosure relates to a set of connectors that connect buckets, such as five gallon buckets, to each other, to the ground, to dimensional lumber and/or to pipe for the purpose of producing objects such as benches, stepstools, tables, sawhorses, shelters, platforms, etc.

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DESCRIPTION OF THE FIGURES

[0005] Figure 1 shows two buckets connected by an example connector.

[0006] Figure 2 shows a cross-section of a portion of the buckets and the connector of Figure 1.

[0007] Figure 3 shows two buckets connected by an example connector.

[0008] Figure 4 shows a cross-section of a portion of the buckets and the connector of Figure 3.

[0009] Figure 5 shows a top perspective view of the example connector of Figure

1.

[0010] Figure 6 shows a side view of the connector of Figure 5.

[0011] Figure 7 shows an end view of the connector of Figure 5.

[0012] Figure 8 shows another top perspective view of the connector of Figure 5.

[0013] Figure 9 shows a top view of the connector of Figure 5.

[0014] Figure 10 shows a bottom perspective view of the connector of Figure 5.

[0015] Figure 11 shows a bottom view of the connector of Figure 5.

[0016] Figure 12 shows a bucket with the connector of Figure 5 and boards extending therefrom.

[0017] Figure 13 shows two buckets with the connectors of Figure 5 with boards extending therebetween.

[0018] Figure 14 shows a bucket with the connector of Figure 5 and boards extending therefrom.

[0019] Figure 15 shows the bucket, connector, and boards of Figure 14.

[0020] Figure 16 shows another example connector,

[0021] Figure 17 shows other example connectors connected to a bucket.

[0022] Figure 18 shows other example connectors connected to a bucket.

[0023] Figure 19 shows one of the connectors of Figure 18.

[0024] Figure 20 shows one of the connectors of Figure 18.

[0025] Figure 21 shows the connector of Figure 20.

[0026] Figure 22 shows two buckets connected by another example connector. [0027] Figure 23 shows a plurality of buckets connected by a plurality of connectors.

[0028] Figure 24 shows a bucket with an example stabilizing base connector.

[0029] Figure 25 shows a bucket with an example leveling base connector.

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[0032]

[0033]

[0034]

[0035]

[0036]

[0037]

[0038]

Figure 26 shows a bucket with another example base connector with

Figure 27 shows a bucket with an example variable angle base connector. Figure 28 shows a bucket with an example vertical lumber connector. Figure 29 shows a bucket with an example joist hanger connector.

Figure 30 shows a bucket with another example connector,

Figure 31 shows a bucket with an example vertical pipe connector.

Figure 32 shows a bucket with an example horizontal pipe connector. Figure 33 shows a bucket with another example connector.

Figure 34 shows a bucket with another example connector.

DETAILED DESCRIPTION

[0039] The present disclosure relates to connectors that couple five gallon buckets to each other, to the ground, to dimensional lumber and/or to pipe for the purpose of producing useful objects such as benches, stepstools, tables, sawhorses, shelters, and platforms.

[0040] By using the connectors described herein, the buekets can do the same jobs as traditional sawhorses, concrete blocks, metal scaffolding, and workmatestyle benches, as well as have additional utility.

[0041] The connectors themselves may be primitive devices that perform a single function or may be composite devices that can perform more than one primitive function. The primitive devices include bucket-to-bucket connections, bucket-toground connections, bucket-to-lumber connections and bucket-to-pipe connections and connector-to-connector connections.

[0042] The example connectors disclosed herein work by allowing a user to do one or more of the following, while still retaining the integrity of the bucket. In some examples, this can be accomplished without tools or modifications needed to the buckets themselves.

[0043] Examples of such uses include:

· attach two buckets to each other either top to bottom, top to top bottom to bottom or side to side;

β attach a bucket to plywood or sheathing;

• attach a bucket to fiat ground securely;

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» attach a bucket to dimensional lumber such as a 2x4; and • attach a bucket to pipe easily such as 4” diameter PVC pipe.

[0044] With the ability to make the above connections quickly, the users can create structural elements that can be configured intuitively and quickly to build a variety of elements that could include:

• short or tall workbench or table;

• scaffolding ;

• stage;

» wood stacking platform;

• sawhorses - infinitely adjustable in length and width;

« portable step up for painting;

• garage/work-site shelves;

• bench;

« work hammock;

» non-flat storage;

® scaffold on a hill or incline;

® tarp tent to cover boats etc.;

« green house cover for gardens;

• soccer/sports goals;

• work light supports;

• temporary shelters;

® volleyball net;

• scaffolding adapted to stairs; and • bridge (e.g., to cross a body of water, like a creek).

The connectors can be sold in kits that allow the connectors to be used to assemble different structures.

[0045] In addition to the above, the buckets can be filed with rocks, water, sand, etc., to add stability. The buckets can also still be used to hold tools, lights, screws, etc. when used alone or structurally, as shown in several of the figures.

[0046] Example configurations are reflected in Figures 1-34. These figures reflect the multiple different configurations that could be used to create the connector. Some examples are:

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PCT/US2010/050885 * a solid “ring” that the bucket snaps into that facilitates connecting the buckets and structural elements - see, e.g., Figures 5-11 and 16; and « “stick” or “block” shaped elements that attach to the bucket bottom or top that can be used alone or can be attached to additional “sticks” to create additional utility - see, e.g., Figures 17-21.

[0047] Referring now to Figures 1 and 2, there are many methods by which a connector can be attached to a bucket. One method of attachment is to snap the connector on in the same manner that a bucket lid snaps on. Since the bucket has a slight taper, the connector can be press fit into place on the bucket. Additionally, latches, straps, screws, etc. could be used.

[0048] In Figure 1, a first five gallon bucket 110 is coupled to a second, inverted bucket 112 using a connector 120. Generally, the connector 120 engages each of the buckets 110,112 similar to that of a lid to couple the connector 120 to each of the buckets 110, 112.

[0049] As shown in Figure 2, the connector 120 includes a groove 115 into which an open end surface 114, 116 of each of the buckets 110, 112 can be inserted to form a structure 100. A lip 122 formed by the connector 120 engages the surface 114 of the bucket 110 to connect the bucket 110 to the connector 120,

[0050] In this example, the structure 100 can be used for many of the applications described above, such a scaffolding, part of a sawhorse, etc.

[0051] For example, as shown in Figures 3 and 4, a structure 200 is created with the bucket 112 inverted so that a closed end 118 of the bucket 112 is connected to the connector 120. Member 124 formed by the connector 120 engages an outer surface 119 of the closed end 118 to connect the bucket 112 to the connector 120.

[0052] Referring now to Figures 5-11, the connector 120 is shown in isolation.

The connector 120 includes several features that allow the connector 120 to be used in a variety of contexts. The connector 120 is one example of a composite device capable of performing more than one primitive function.

[0053] The connector 120 has a first connector side 111 and a second connector side 113. The connector 120 includes two parallel slots 210, 212 formed by protrusions 202, 203, 204, 205, 206, 208 for holding a cross member, such as a piece of 2x4 dimensional lumber of any length, securely in the horizontal orientation (with the 4” dimension parallel to the ground). Tabs 222 are formed on protrusions 206,

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208 and extend into the slots 210, 212 to capture the lumber to couple the lumber to the connector 120. Relief apertures 223 are formed behind the tabs 222 within the protrusions 206, 208 to allow the tabs 222 to flex so that the lumber can be “snapped in” to the slots 210, 212 easily yet contain the lumber securely once in place. In other words, the relief apertures 223 allow the tabs 222 to “flex” so the tabs 222 can move out of the way to let the board pass into and out of the slots 210, 212.

[0054] In addition, dimples 233 are formed to allow for the connector 120 to snugly grip dimensional 2x4 lumber with varying widths due to normal manufacturing variations, moisture content, etc.

[0055] For example, as shown in Figures 12 and 13, boards 310, 312 and 314,

316 are connected to connectors 120. The boards 310, 312, 314, 316 can be coupled and uncoupled from within the slots 210, 212 by sliding the boards into the slots 210, 212 so that the tabs 222 engage the boards.

[0056] Referring again to Figures 5-11, the connector 120 also includes a center slot 240 formed by protrusions 202, 203, 204, 205, 206, 208 for holding a cross member, such as a 2x4 piece of dimensional lumber of any length securely in the vertical orientation (with the 4” dimension perpendicular to the ground). In the example shown, the center slot 240 is oriented perpendicular to the slots 210, 212, although other orientations can also be used.

[0057] The connector 120 also includes recesses 250. The recesses 250 allow a fastener, such as a screw or nail, to be placed to securely connect the lumber to the connector 120.

[0058] Other configurations are possible. For example, lumber of different sizes (e.g., 2x6, 4x6, etc.) can be accommodated by the connector 120. In addition, the orientation and size of the slots can be modified, as described further below.

[0059] The second connector side 113 of the connector 120 also includes grooves 262 formed in an extension member 264. The grooves 262 are sized to receive horizontal pipes extending across the connector 120. See, e.g., Figure 32. In addition, the connector 120 includes a groove 266 into which the open end surface

114, 116 of each of the buckets 110, 112 can he inserted to couple the buckets to the connector 12Q. A diameter of an inner surface 268 of the connector 120 is sized to engage the closed end 118 of the bucket 112 to form an interference fit,

[0060] For example, referring now to Figures 14 and 15, a connector 420 is shown. The connector 420 includes protrusions 422, 424,426 that allow two 2x4

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Other embodiments are possible.

[0061] In these examples, the connectors 120, 420 can be configured to be connected to the top or bottom of the buckets 112, 114 while maintaining the structural and watertight integrity of the buckets. Heavy weight (water, rocks, screws, tools etc.) can be added to the buckets 112, 114 before the connector 120 is attached to add stability to the structure being built.

[0062] In other examples, the connectors can be ring-shaped or have alternative shapes.

[0063] In Figure 16, a ring-shaped connector 500 is shown. The connector 500 includes a groove 502 formed on each side of the connector 500 so that one or two buckets can be coupled to the connector 500. In addition, the connector 500 forms opposing slots 504 on each side of the connector 500 so that a cross member, such as a 2x4 board, can be extended through the slots 504 to build structures.

[0064] The connectors need not be ring-shaped. Rather, single blocks, rectangular shapes or organic forms can be equally effective.

[0065] For example, a single connector block can be connected to a bucket alone or in pairs to control connection of the bucket to another bucket and/or the placement of lumber or pipe. For example, as shown in Figure 17, connector blocks

510 are coupled at periodic intervals (e.g., at 90 degree intervals) along the open end surface 116 of the bucket 112. Each of the connector blocks 510 defines grooves 512 in both sides of the blocks 510 to allow the blocks 510 to be coupled to the bucket 112.

[0066] In another example shown in Figures 18-21, rectangle connectors 530,

540 are configured to span the bqcket diameter to control lumber and/or connect buckets together.

[0067] The connector 540 includes opposing side members 541 forming grooves 542 that are positioned to engage the open end surface 116 of the bucket 112. A cross-member 544 spans between the two side members 544. The connector 530 similarly includes side members 541 forming grooves 542. In addition, the crossmember 546 spanning between the side members 541 includes a slot to accept the cross-member 546 of the connector 540 when positioned at a 90 degree angle with respect to one another.

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[0068] The rectangular shape of the connectors 530, 540 spans the bucket diameter with efficiency and can be used to control lumber or pipe singly or in pairs. [0069] In the examples shown, any lumber coupled to the connectors 530, 540 intersects at right angles above the bucket. However, in alternative applications, angles less than or greater than ninety degrees may be used.

[0070] With the ability to make the above connections quickly, the users can create structural elements that can be configured intuitively and quickly to build a variety of useful structures.

[0071] For example, bucket to bucket connections allow one bucket to be joined 10 to another so that they may be stacked. Bucket to bucket connections exist in four general forms: lid-to-lid (Figures 1-2), base-to-base (see connector 600 shown in Figure 22), lid-to-base (Figures 3-4), and side-to-side.

[0072] As shown in Figure 23, side-to-side connectors 650 connect buckets, not along the axis of the bucket as in the previously described connectors, but radial to the axis of the bucket, either with the lid ends facing the same direction or in opposite directions. These connectors 650 attach to the buckets in a manner consistent with the other connectors and attach to the adjacent connectors 650 by snaps. The connectors 650 are generally square, but other geometric shapes (such as triangles, hexagon etc.) could be used as well. The connectors 650 can be used for building walls or storage bins, and can be made with lids and without.

[0073] Referring now to Figures 24-27, bucket-to-ground connections improve the interface between the bucket and the earth, floor, sidewalk, or street, etc. Bucket-to-ground connections exist in four general forms: stabilizing base, leveler, spiked, cushioned, wheeled or weighted bases, and variable angle base.

[0074] As shown in Figure 24, a stabilizing base 710 includes an aperture 712 sized to receive a closed or open end of the bucket 112. The stabilizing base 710 is a connector that can be attached to either end of the bucket 112 to enlarge the footprint and add stability to the construct.

[0075] As shown in Figure 25, a leveling base 720 is a two-part connector that allows a bucket column 722 to be raised or lowered in directions 724 relative to the ground. One side 726 of the base 720 connects to the bucket 112, while the other side 728 translates within that part and locks in continuous or discreet positions, effectively increasing or decreasing the distance from the bucket 112 to the ground.

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One translation mechanism is a large thread, although bayoneting or pinning the translating part into discreet positions could algo be used.

[0076] Spiked, cushioned, wheeled, and/or weighted bases include special interfaces with the ground. It may be desirable to have bases with a cushioned, non5 marring surface, or non-slip surface when working in doors. Alternatively, it may be desirable to have a spiked surface or a surface through which one may drive spikes for securing the construct when working on grass or dirt. Adding casters for mobility or weight in the form of sand, water or metal may also add utility.

[0077] For example, referring now to Figure 26, a connector 740 includes a plurality of spikes 742 extending from the connector. The spikes 742 can be driven into a surface, such as dirt, to stabilize the connector 740 and attached bucket 112. The connector 740 can also include holes for driving stakes through the connector 740 and into the ground.

[0078] In Figure 27, a variable angle base 750 is used to level a construct on uneven ground. The base 750 includes a first part 752 that attaches to the bucket 112 and a second pail 754 that rotates at an angle 758 relative to the first part 752 and interfaces with the ground, The second part 754 can rotate freely or be fixed in place at a discreet angle.

[0079] Bucket-to-lumber connections connect a bucket to dimensional lumber or sheathing. Types of bucket-to-lumber connections include: lumber-on-end, lumberon-side, lumber vertical, joist hanger, and sheathing,

[0080] Examples of the lumber-on-end and lumber-on-side configurations are shown in Figures 12-15. Other configurations are possible.

(0081] A vertical lumber connector 810 is shown in Figure 28. The connector

810 allows the use of dimensional lumber 812 as a post, and the bucket 112 becomes a stable base for the post. The lumber 812 slides through an aperture 811 in the connector 810 and rests on the bottom of the bucket 112. Stability can be added by filing the bucket 112 with sand or gravel and by securing the post to the conneetor 810 with a fastener, such as a screw or clamp.

[0082] Referring now to Figure 29, a joist hanger bucket connector 820 includes a pocket 822 positioned below the open end surface 116 of the bucket 112. This allows the dimensional lumber 824 to be suspended from the side of the bucket 112 rather than pass the lumber 824 over the top of the bucket 112. This allows one to link one bucket column to another using lumber to add stability to the construct.

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[0083] Plywood/sheathing connectors function similarly to dimensional lumber connectors, with the difference being the thickness of the board being accommodated. For example, in one alternative embodiment shown in Figure 30, a connector 832 includes disks 833 that engage a bottom surface of a plywood sheet

834. The disks 833 have a roughened or sticky top surface that minimizes any tendencies of the sheet 834 to slip.

[0084] Bucket-to-pipe connections connect a bucket to a pipe. Types of bucketto-pipe connections include vertical pipe and horizontal pipe. In some examples, pipe can include conduit through which a fluid could flow, as well as the handle of a rake or shovel, etc.

[0085] Referring to Figure 31, a vertical pipe connector 910 allows one to use a pipe 914 as a post, and the bucket 112 becomes a stable base for the post. The pipe 914 slides through an aperture 912 formed in the connector 910 and rests on the bottom of the bucket 112. Stability can be added by filing the bucket 112 with sand or gravel and by securing the post to the connector 910 with a fastener, such as a screw, clamp or adhesive.

[0086] Referring to Figure 32, a horizontal pipe connector 920 allows one to attach pipes 924 to the bucket 112 in a horizontal orientation. One side of the connector 920 connects to the bucket 112, and the other side receives the pipes 924.

The pipes 924 can rest within a semi-circular groove 922 formed in the connector 920, snap in place or be slipped into a cylindrical receiver.

[0087] In some cases, it may be advantageous to connect bucket connectors to each other in order to support modularity or add degrees of freedom. Methods for achieving this may include threaded connections, snaps, latches, etc.

[0088] There are many methods by which the lumber can be captured by the connectors. The lumber can snap into place, latch in, be secured by fasteners (i.e. screws, nails), straps or adhesive, or enveloped by a connector 930, as shown in Figure 33. The connector 930 defines two apertures 932, 934 through which 2x4 boards 936, 938 extend.

[0089] Referring to Figure 34, another effective method of securing lumber 958,

959 to the bucket 112 is a connector 950 including a first part 952 that forms slots for the lumber 958, 959. A middle portion 956 of the connector 950 includes a second part 954 that rotates 90 degrees to capture (as shown) and release the lumber 958, 959.

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[0090] Various embodiments are described above. These embodiments are examples only. Other variations are possible, and features of different embodiments can be combined to form other variations.