Light weight ladder systems and methods

1. A method for manufacturing a ladder, the method comprising:

pultruding a fiber reinforced thermoplastic polymer material to form at least one rail;

cutting the at least one rail to a predetermined length;

substantially cooling and setting the thermoplastic polymer;

reheating the at least one rail to a temperature proximate a glass transition temperature corresponding to the thermoplastic polymer material and applying a force to the at least one rail in a direction substantially transverse to the at least one rail's predetermined length to form a curvature therein subsequent the reheating, the curvature including a flared portion, a straight portion, and a curved region providing a transition therebetween;

holding the at least one rail at the curvature for a time selected for the at least one rail to take on the curvature substantially permanently; and

assembling the at least one rail into a ladder.

2. The method of claim 1 , wherein the assembling further comprises distributing a plurality of rungs along the predetermined length of the at least one rail and coupling each of the plurality of rungs to the at least one rail.

3. The method of claim 2 , further comprising forming the curved region of the at least one rail as a shape selected from the group consisting of a substantially single continuous arc substantially tangent with the flared portion, a series of angled bends spaced from one another along the curved region, and a single continuous bend connecting the straight portion to the flared portion.

4. The method of claim 3 , wherein the assembling the at least one rail into a ladder further comprises inserting an extension to slide longitudinally within the straight portion of the at least one rail.

5. The method of claim 4 , further comprising forming the at least one rail to exhibit a cross-sectional shape, as taken substantially transverse to the at least one rail's predetermined length, including forming the cross-sectional shape as an open shape comprising first and second retainers connected by a web.

6. The method of claim 5 , further comprising providing the first and second retainers to capture the extension within, and in sliding engagement with, the straight portion.

7. The method of claim 6 , further comprising configuring the first retainer to have a rib extending away therefrom and shaped to secure the plurality of rungs thereto.

8. A method for manufacturing a ladder, the method comprising:

forming a rail including:

pultruding in a longitudinal direction, the rail having a cross-sectional shape; cutting the rail to a predetermined length at a distal end;

forming the cross-sectional shape to comprising first and second retainers connected by a web;

applying a force in a direction substantially transverse to a longitudinal extend of the rail to form a nonlinear segment therein, the nonlinear segment including a flared portion, a straight portion, and a curved region providing a transition therebetween, wherein forming the curved region comprises bending the rail into a shape selected from the group consisting of a substantially single continuous arc substantially tangent with the flared portion, a series of angled bends spaced from one another along the curved region, and a single continuous bend connecting the straight portion to the flared portion; and

holding the rail at a configuration of the nonlinear segment for a time sufficient for the rail to take on the configuration substantially permanently; and

assembling the rail into a ladder including:

longitudinally distributing, along the flared portion and straight portion, rungs extending laterally, the flared portion being located to support the ladder on a supporting surface to increase stability thereof;

inserting an extension to slide longitudinally within the straight portion;

providing the first and second retainers to capture the extension within, and in sliding engagement with, the straight portion; and

configuring the first retainer to have a rib extending away therefrom and shaped to secure the rungs thereto.

9. The method of claim 8 , wherein the pultruding further comprises pultruding fiber reinforced thermoset polymer matrix.

10. The method of claim 9 , further comprising curing the fiber reinforced thermoset polymer matrix.

11. The method of claim 8 , wherein the pultruding further comprises pultruding a reinforced fiber in a thermoplastic polymer material.

12. The method of claim 11 , further comprising substantially cooling and setting the thermoplastic polymer material.

13. The method of claim 12 , further comprising reheating the at least one rail to a temperature proximate a glass transition temperature corresponding to the thermoplastic polymer material before applying the force to the at least one rail.

14. A method for manufacturing a ladder, the method comprising:

pultruding in a longitudinal direction, a rail having a cross-sectional shape, including forming the rail of a reinforced fiber in a thermoplastic polymer matrix;

cutting the rail to a predetermined length at a distal end;

selecting a time to provide for substantial cooling and setting of the thermoplastic polymer matrix;

reheating the rail to a temperature proximate a glass transition temperature corresponding to the thermoplastic polymer matrix;

applying a force in a direction substantially transverse to a longitudinal extend of the rail to form a nonlinear segment therein, the nonlinear segment including a flared portion, a straight portion, and a curved region providing a transition therebetween;

holding the rail at a configuration of the nonlinear segment for a time sufficient for the rail to take on the configuration substantially permanently; and

assembling the rail into a ladder.