NZ554190A - Protector caps for tube, fence standard, or reinforcing rod - Google Patents

Abstract

An end-cap for use on reinforcing bars, scaffolding tubes, Waratah posts and the like used in the building and construction industries, to reduce potential dangers to which workers are exposed, is disclosed. Various arrangements of projections and recesses within the cap are described.

Description

554190 *10055648523* PATENTS FORM NO. 5 Ourref: HAW506681NZPR NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION IMPROVEMENTS IN AND IN RELATION TO CAPS We, Hl-Q Electronics Ltd, a New Zealand company of 6C Douglas Alexander Parade, Albany, North Shore City 0632, New Zealand hereby declare the invention, for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: Intellectual property office of n.z 2 0 MAR 2008 RECEIVE P 300869414_1. DOC: HAW :QAKLD 554190 2 IMPROVEMENTS IN AND IN RELATION TO CAPS FIELD OF THE INVENTION This invention relates to end caps and more particularly to protection end caps used in building and construction to reduce a potential danger to which workers are exposed where elongate articles project in a direction where they may impale or otherwise injure a worker.

BACKGROUND ART Protection end caps are known in the building and construction industry and have indeed become mandatory use in relation to, for example, the ends of reinforcing bar starter rods and other elements of building armature. Such end caps are generally provided with a relatively 15 rounded upper end portion, and a recess therebeneath designed to fit over specific bar sizes.

A number of difficulties have been experienced with presently available end caps, which limit their use or create significant inconvenience on a construction site. End caps can be either size specific, as it relates to the particular reinforcing bar with which they are intended to be 20 used, or size range specific. As a result, it is often necessary for workers to suffer the inconvenience of having to have a range of end caps suitable for the specific material being used, coupled with the inevitable lost time on the site. Where only incorrectly sized or types of end caps are available, inevitably there is lost time sourcing alternatives, particularly where use is mandated, or increased danger when not and there is a delay in use.

While reinforcing bar protection is one area where end caps are used significantly, there are a number of other potential danger areas to which workers are exposed, including posts, scaffolding and the like, however these require a wider range of end caps to be accessible and lead to increased stock requirements for compliance and lost time for sourcing and customers. 300864915_1 .DOC 554190 3 OBJECT OF THE INVENTION It is an object of this invention to come some way to addressing the provision of protective end 5 caps, or at least provide the public with a useful choice.

Other objects of this invention will become apparent from the following description. SUMMARY OF THE INVENTION According to one aspect of this invention there is provided an end cap for engaging over an end portion of an elongate member, such as a post end, tube, bar or the like, the end cap including: • a body portion including a primary recess in an underside thereof, the primary recess being defined at least partly by a skirt which projects from an end cap head portion; • projections arranged in the primary recess to project from the head portion to define a predetermined dimension sub recess between the skirt and the projections, the projections and skirt being capable of engaging the end cap over an end portion of a first form of an elongate member; and • secondary recesses defined by edge portions of the projections arranged in an orientation adapted for alternative engagement of the end cap over an end portion of a second form of an elongate member; wherein the end cap is adapted to frictionally engage the elongate member when in use to retain the end cap in position.

Preferably the end cap is capable of engaging over the end of an elongate member of a predetermined size range.

Preferably the projections and skirt are capable of engaging the end cap over an end portion of 30 an elongate member in the form of a tube.

Preferably the secondary recesses are adapted for engagement of the end cap over an end portion of an elongate member in the form of a post end.

Preferably when at least one peripheral portion of the post end is engaged in a secondary recess it is adjacent the skirt.

Preferably the secondary recesses are positioned to provide a pathway that '^lleS7^lpropertv7 a post end in the form of a Waratah post end. I OFF/ce of n.z J | M NOV 2008 I 301007536-1 [RECEIV £ D 554190 4 Preferably the pathways are provided in an approximate "Y" shape format.

Preferably the edge portions are spaced sufficiently apart such that they will frictionally impinge upon the adjacent surfaces of Waratah post end portion when in use.

Preferably the secondary recesses defined by the edge portions of the projections are reinforced by enlargements at or adjacent the edge portions of the projections.

Preferably the enlargements provide increased friction points for engagement with the interior 10 of a tube.

Preferably the sub recess between the skirt and the projections is a recessed annular sleeve extending within the primary recess.

Preferably web portions are positioned in the primary recess internally of the projections and extending toward one another, to define between their adjacent edges thereof, a recess of predetermined dimensions for frictionally engaging the end portion of a third form of an elongate member.

Preferably the recess defined between the adjacent edges of the web portions is for frictionally engaging the end portion of an elongate member in the form of a bar.

Alternatively the recess defined between the adjacent edges of the web portions is for frictionally engaging the end portion of an elongate member in the form of a tube.

Preferably at least one of the web portions is arranged to be substantially bifurcated.

Preferably the web portions are connected with adjacent portions of the projections and the interior of said end cap head to mutually stabilise each other.

Preferably the web portions are arranged in such a position as to further define a passageway in the primary recess whereby a flange/flanges of a Waratah post can engage and wherein the edges of the web portions are arranged to impinge against the flange(s) to cooperatively frictionally engage the end cap on the post. 301007536-1 intellectual property office OF M i 1 4 NOV 2008 RECEIVED 554190 Preferably the secondary recesses and/or web portions are each provided to present a tapered entry for engagement of the end of an elongate member.

Preferably the end cap is integrally formed in mouldable settable material.

Preferably the end cap is integrally formed in injection moulded plastics material and incorporates a predetermined deformability.

Preferably the web portions and/or projections are formed to be deformable to accommodate 10 predetermined variations in dimension of the end of an elongate member with which the end cap is engageable.

According to a second aspect of the invention there is provided a method of covering the end of an elongate member, the method including the step of placing an end cap according to the first 15 aspect of the invention on an end portion of the elongate member.

According to a third aspect of the invention there is provided the use of an end cap according to the first aspect of the invention in covering an end portion of an elongate member.

Other aspects of this invention will become apparent from the following description.

Modifications are envisaged and may be incorporated without departing from the scope or spirit of the invention.

BRIEF DESCRIPTION OF THE FIGURES One form of the invention will now be described with reference to the accompanying drawings in which: Figure 1: shows a perspective view of the end cap of the invention, showing typical engagement on a portion of a reinforcing bar.

Figure 2: shows a plan view of the recessed underside of the end cap in a pre-engagement condition. 300864915_1 .DOC 554190 6 Figure 3: Figure 4: Figure 5: Figure 6: Figure 7: DETAILED DESCRIPTION The invention generally relates to protection end caps used in building and construction to 20 reduce a potential danger to which workers are exposed where elongate articles, such as post ends, tubes, bars or the like, project in a direction where they may impale or otherwise injure a worker.

The invention is preferably provided to be integrally moulded in plastics material having a 25 degree of resilience, but remaining sufficiently stiff so that as a unitary member, when engaged on the end of an elongate member, such as a post end, tube, bar or the like, it provides the required degree of resistance to impact and dislodgement to operate as a protector end cap, to reduce the likelihood of injury should a worker come into contact with it.

In the preferred form of the invention, the end cap is injection moulded in, for example, linear low density or high density polyethylene, however it is in no way limited to this form of construction. It is furthermore envisaged that as technology develops, the end cap could well be formed in materials which are environmentally benign or break down rapidly, or could be produced in suitable recycled materials and the like. shows a substantially cross sectional side view of the inverted end cap of Figure 2 according to lines AA of Figure 2. shows a partial cross sectional side view of the end cap according to lines BB of Figure 2. shows a base view of the end cap of Figure 2 when it is engaged over a portion of tube T. shows a base view of the said end cap when it is engaged over an end portion of a flanged Waratah post W. shows a similar view to Figures 5 and 6, however, showing the end cap engaged over an end portion of a reinforcing bar R. 554190 7 It is envisaged that the end cap will be provided in a variety of sizes to suit typical application usage. Preferably, the end cap is provided in material and of a construction as described hereinafter, which enables the end cap to be used within a predetermined size range of elongate member ends such that users will not have to stock a specific size range for every 5 envisaged use, and that some sizing variability can be "built in". An ability for the end cap to accommodate inevitable burring of ends of elongate members where, for example they have been driven, or where the end portion is in other ways somewhat deformed from the original shape is also envisaged.

Referring specifically to Figures 1 and 2, the end cap as generally indicated by arrow 1 presents outwardly a body portion 2 having a head portion 3 having a substantially cylindrical skirt 6, which extends from a preferably rounded or radiused transition 5 from the head portion 3, so that the skirt 6 defines a primary recess 7 therebeneath as a substantially cylindrical blind opening.

A substantially cross sectional side view of the inverted end cap of Figure 2 according to lines AA is shown in Figure 3. The primary recess 7 in the preferred form of the invention, wherein it is outwardly defined by interior surfaces 6a of the annular skirt 6, can be seen in this Figure. Whilst the invention is described with reference to the skirt 6 being substantially cylindrical, it is 20 to be appreciated that in alternative forms of the invention, the end cap 1 and skirt 6 could define a recess 7 of a different shape, for example a polygonal shape, square, octagonal, triangular or the like depending on the elongate member ends for which it is designed to engage.

In the present form of the invention the underside 3a of the head portion 3 of the end cap 1 is provided to define in conjunction with the interior surfaces 6a of the skirt 6, a primary recess 7, which will provide a friction fit over the end of a portion of, for example, a tube T (see Figure 5), such as a scaffolding tube and the like. It is envisaged that the material from which the end cap 1 is formed will incorporate a degree of "stretch", such that the skirt 6 can be engaged over a 30 predetermined variety of sizes or, should the end of the tube T be deformed, such as by burring, out of round and the like.

Internally of the primary recess 7, the underside 3a of the head portion 3 can have reinforcing ribs thereacross (not shown), if required, to maintain a sufficient degree of strength in the head 35 portion 3 so as to resist puncturing, cracking and the like thereof, although this is no way 300864915_1.DOC 554190 8 essential to the invention. These ribs can be arranged to also graphically indicate the proposed forms of engagement for the end cap 1 on the various post end portions with which the end cap 1 is intended to be used.

As shown in Figure 2, spaced from the interior surfaces of the skirt 6 there is provided a plurality of projections 9 having outer portions 9a opposing the inner skirt surface 6a so as to define a substantially annular sub recess portion 11 in the primary recess 7 between the skirt 6 and the projections. It will be appreciated that the positioning of the projections 9 is such that they fall into a predetermined dimension "castellated" annular inner ring (relative to the skirt 6) such that the projections 9 and skirt controllably engage the scaffolding tube T as is shown in Figure 5.

It will be appreciated that the degree of resilience which exists between the projections 9, skirt 6 and head portion 3, together with the individual nature of the projections 9 each separated by pathway portions 12, facilitates a degree of "accommodation" of sizes of tubes in the annular sub-recess portion 11 to facilitate accommodation of a variety of scaffolding tube T sizes within a predetermined range for the end cap 1.

The preferred form of the invention facilitates alternative use of the end cap 1 of this invention to also engage over a post end configuration as shown in Figure 6. In this form of the invention, the post end configuration with which the end cap 1 is intended to be used is a so called "Waratah" post having a generally "Y" shaped flanged cross-section W within the predetermined size band.

It will be appreciated that to facilitate such engagement, the pathways 12 are provided in an approximate "Y" shaped format, and the projections 9 are arranged in a way so as to provide edge portions 13 of the pathways 12 (obscured from view in Figure 6) that are spaced sufficiently apart such that they will frictionally impinge upon the adjacent surfaces of each portion of the post W flanges when the end cap 1 is engaged there over. The edge portions 13 of the pathways 12 in the preferred embodiment shown in the Figures include enlargements 14, but these enlargements 14 are not essential as would be known to one of skill in the art.

In the preferred form of the invention, and with particular reference to Figure 6, preferably the outer portions 9a defining the pathways 12 are arranged with enlargements 14 thereon for 301007551-1 554190 8A additional reinforcing purposes. The enlargements 14 also provide increased friction points for engagement with the interior of a scaffolding tube T when engaged therewith as shown in 301007551-1 I M NOV 2008 / -5EC£jy£D/ 554190 9 Figure 5. The outer portions 9a of the projections 9 can be tapered at entry to assist engagement of the end cap 1 over the end of the Waratah post W as shown by Figure 6.

Preferably the projections 9 are provided with inwardly directed web portions 21 and the edges 22 of the web portions 21 are arranged to substantially align with and impinge against adjacent opposing surfaces of the post W, however this is not essential to the invention and the end cap 1 is envisaged to be able to accommodate varying sizes of posts W within the primary recess7.

Internally of the projections 9 is defined a medial sub-recess portion 20. This medial sub-recess portion 20 has the web portions 21a,b,c,d,e arranged to extend inwardly thereof, preferably extending from an integral engagement with the head portion 3 through the primary recess 7 toward the opening and providing additionally buttressing to the projections 9.

Referring specifically to Figure 4, the web portions 21 are preferably arranged as inwardly directed and angled "fins" having the web edges 22 tapered or outwardly flared toward the opening of the recess 7. As shown in Figure 7, this tapering or outward flaring of the web edges 22, facilitates engagement of the end of an elongate member, in the form of a reinforcing bar R therewith.

Referring again to Figure 6, it will be appreciated that web edges 22 and the angular alignment of the web portions 21, one relative to the other, are such that said web edges 22 define, internally of the medial sub-recess 20, in this preferred case, a "Y" shape pathway orientation through which the flanges F of the Waratah post W end can be positioned as shown by Figure 25 6.

It will be appreciated that where the end cap 1 is engaged on a Waratah post W of smaller dimensions, whereby edges E of the post W do not impinge upon the skirt 6 inner surfaces 6a, a frictional engagement of the web edges 22 and the post W can alternatively maintain 30 engagement of the end cap 1 on the post W.

In the preferred form of the invention, and as will be seen by the base view drawings of Figures 2, 5, 6 and 7, preferably the web portions 21 are arranged to substantially oppose one another, in this form in a substantially triangulated manner so as to stabilise the end cap 1 on the end of 35 the post W. Preferably the web portions 21 may also be bifurcated as shown in Figure 6, whereby additional stability can be imparted to the engagement between the post W and the [intellectual property) j OFFICE or ISI.Z 301007551-1 I B NOV 2008 RECFlVPn 554190 end cap 1 on impingement of the web edges 22 with adjacent portions of the post W, whilst also retaining the end cap 1 engaged substantially centralised. It will be seen that this is achieved by a edge portion 22 of web portions 21a tending to engage adjacent a "valley" defined by the post W cross section flanges F intersection, whereas the edge portions of 5 bifurcated web portions 21 c and 21 d and 21 e and 21 b impinge on one of the flanges F away from the intersection to prevent unwanted part rotation of the end cap 1 on the post W, which may lead to dislodgement.

It will be appreciated that the respective sizing of the pathways and recesses are provided so 10 as to enable a combination of a predetermined amount of post W deformation, for example burring or bending of the portions with which the end cap 1 must inter-engage, by virtue of the inherent flexibility of the product, the ability for the recess to deform, or be enlarged, by forcing of the end cap 1 thereon. Deflection of one or more of the web portions 21 may occur as the end cap is forced onto the opposed post W end as well.

Returning now predominantly to Figures 1 and 7, it will be also appreciated that the end cap 1 according to this invention can additionally be provided as a protector end cap 1 for a reinforcing bar R substantially in the format as shown in Figure 1 and Figure 7. Used in this manner, it will be appreciated that the end cap 1 may be frictionally engaged with the end of a 20 reinforcing bar R of a diameter falling within a predetermined use range. In this form of the invention, it is to be appreciated that the pathway defined between the web edges 22 also is capable of defining a pre-determinable variably sized area 30 (obscured from view in Figures 1 and 7) into which the end of the bar R can be engaged. By virtue of the flexible nature of the material from which the end cap 1 is formed, and the angular orientation of the web portions 21 25 as has been described with reference to Figure 6, it will be appreciated that the end cap 1 can be engaged onto the end of the reinforcing bar R. This is preferably achieved by a pushing and rotating action, to develop a preferred combination of deflection and formation, facilitated by the web portions 21 and particularly the web edges 22 engaging the adjacent surfaces of the bar R to retain the end cap 1 frictionally in position.

It will be appreciated that the orientation of the web portions 21, facilitates secure engagement of the end cap 1 on the bar R substantially medially or coaxially, yet facilitates the combination of a pre-determined variety of bar R sizes. When used in this way, it is envisaged that the edge 22 of web portion 21a will in most instances impinge against the side of the reinforcing bar 35 substantially orthogonally, yet the edges 22 of web portions 21 b, c, d and e, are deflectable 300864915_1 .DOC 554190 11 away from a rest position as shown in Figure 7, to enable accommodation there between of a bar R of greater dimensions than the dimension between such edges 22 in the rest condition.

As would be envisaged by one of skill in the art once in position of this invention, the bar need not be of a solid cylindrical shape but could be any other suitable shape, such as a tube of suitable diameter.

Whilst in the preferred form of the invention, the web portions 21 are integrally engaged with 10 the end cap head portion 3, it is envisaged that in alternative forms of the invention, some or all of the web portions 21 may be arranged to be at least partially separate from the end cap head portion 3 so as to permit even greater deflection of the web portions 21, such as where a greater range of bar R is required to be accommodated.

Furthermore, it is also envisaged that materials from which the end cap is formed, and the provision of tolerances between the end cap 1 portions which engage respectively the scaffolding tube T, the post W or the reinforcing bar R are arranged to provide the preferred form for frictional engagement, to retain the end cap 1 in position, for example in windy conditions, or upon coming into contact with equipment, machinery and in general use around 20 workers. It is also envisaged that if required, the tolerances can be adjusted so as to facilitate use of the end cap 1 for the purposes of securing sheet material, such as polyethylene sheet, geo textiles, fencing components and the like to posts, for example by engaging the end cap 1 with the respective elongate end member, sandwiching a portion of the sheet therebetween, thus providing a convenient means for securement of such sheet materials on a building and 25 construction site.

Whilst the invention has been described with reference to the formation of an integrally formed unit in a semi resilient and plastic material, it is envisaged that in alternative forms of the invention where and when for example, use requirements so dictate, the end cap 1 can be 30 formed in alternative and more rigid materials including ceramics, metal and the like.

Whilst the invention has been described with reference to engagement with a post W, it is to be appreciated that the recess 7, projections 9, web portion 21, skirt 6 and related portions can be alternatively arranged to provide a end cap 1 for alternative post arrangements, such as, but 35 not by way of limitation, those incorporating a cross configuration, triangular, square, "H" or "I" configuration and the like. 301007551-1 554190 12 In the preferred form of the invention the material from which the end cap 1 is formed is preferably provided in a high visibility material, for example in a plastics which is brightly coloured, typically in what is known in the trade as "day glo" colours. It is also envisaged that 5 the end cap 1 may be formed in or coated with luminous material such that not only is the end cap 1 highly visible in daylight or artificially lit conditions, but also has luminous properties, enhancing safety in no or low light conditions.

In one form of the invention, preferably the die used for manufacturing the end cap 1 may have 10 one or a series of inserts therein, to enable the end cap 1 to carry a manufacturers or a sponsoring company trade mark, specific technical data relevant to that particular end cap and other material such as reorder contacts and the like. In such circumstances it is envisaged that a portion of the die which forms the outer surface of the head portion 3 can be provided as an insert to facilitate variation in the nature of any information which may be provided with the end 15 cap and further, may facilitate the convenient facilitation of bi-moulded labelling, surface treatments more readily able to receive marking for construction site set out and other information as may be required.

Whilst the invention has been described with reference to one embodiment, modifications are 20 envisaged and may be incorporated without parting from the scope or spirit of the invention as hereinbefore defined. 300864815_1, DOC 554190 13

Claims (26)

WHAT WE CLAIM IS:

1. An end cap for engaging over an end portion of an elongate member, such as a post end, tube, bar or the like, the end cap including: • a body portion including a primary recess in an underside thereof, the primary recess being defined at least partly by a skirt which projects from an end cap head portion; • projections arranged in the primary recess to project from the head portion to define a predetermined dimension sub recess between the skirt and the projections, the projections and skirt being capable of engaging the end cap over an end portion of a first form of an elongate member; and • secondary recesses defined by edge portions of the projections arranged in an orientation adapted for alternative engagement of the end cap over an end portion of a second form of an elongate member; 20 wherein the end cap is adapted to frictionally engage the elongate member when in use to retain the end cap in position.

2. The end cap of claim 1 wherein the end cap is capable of engaging over the end of an elongate member of a predetermined size range. 25

3. The end cap of any one of the preceding claims wherein the projections and skirt are capable of engaging the end cap over an end portion of an elongate member in the form of a tube. 30

4. The end cap of any one of the preceding claims wherein the secondary recesses are adapted for engagement of the end cap over an end portion of an elongate member in the form of a post end.

5. The end cap of claim 4 wherein when at least one peripheral portion of the post end is 35 engaged in a secondary recess it is adjacent the skirt.

6. The end cap of claim 4 or claim 5 wherein the secondary recesses are positioned to provide a pathway that can accommodate a post end in the fornjlMTiO^jag^ office-' of rvTz 301007569-1 I 1 4 NOV 2008 OPrv»-.> 14

7. The end cap of claim 6 wherein the pathways are provided in an approximate "Y" shape format.

8. The end cap of claim 6 wherein the edge portions are spaced sufficiently apart such that they will frictionally impinge upon the adjacent surfaces of Waratah post end portion when in use.

9. The end cap of any one of the preceding claims wherein the secondary recesses defined by the edge portions of the projections are reinforced by enlargements at or adjacent the edge portions of the projections.

10. The end cap of claim 9 wherein the enlargements provide increased friction points for engagement with the interior of a tube.

11. The end cap of any one of the preceding claims wherein the sub recess between the skirt and the projections is a recessed annular sleeve extending within the primary

12. An end cap of any one of the preceding claims wherein web portions are positioned in the primary recess internally of the projections and extending toward one another, to define between their adjacent edges thereof, a recess of predetermined dimensions for frictionally engaging the end portion of a third form of an elongate member.

13. The end cap of claim 12 wherein the recess defined between the adjacent edges of the web portions is for frictionally engaging the end portion of an elongate member in the form of a bar.

14. The end cap of claim 12 wherein the recess defined between the adjacent edges of the web portions is for frictionally engaging the end portion of an elongate member in the form of a tube.

15. The end cap of any one of claims 12 to 14 wherein at least one of the web portions is arranged to be substantially bifurcated. recess. 301007569-1 11 NOV 2008 554190 15

16. The end cap of any one of claims 12 to 15 wherein the web portions are connected with adjacent portions of the projections and the interior of said end cap head to mutually stabilise each other. 5

17. The end cap of any one of claims 12 to 16 wherein the web portions are arranged in such a position as to further define a passageway in the primary recess whereby a flange/flanges of a Waratah post can engage and wherein the edges of the web portions are arranged to impinge against the flange(s) to cooperatively frictionally engage the end cap on the post. 10

18. The end cap of any one of claims 12 to 17 wherein the web portions are each provided to present a tapered entry for engagement of the end of an elongate member.

19. The end cap of any one of the preceding claims wherein the secondary recesses are 15 provided to present a tapered entry for engagement of the end of an elongate member.

20. The end cap of any one of the preceding claims wherein the end cap is integrally formed in mouldable settable material. 20

21. The end cap of claim 20 wherein the end cap is integrally formed in injection moulded plastics material and incorporates a predetermined deformability.

22. The end cap of any one of the preceding claims wherein the projections are formed to be deformable to accommodate predetermined variations in dimension of the end of an 25 elongate member with which the end cap is engageable.

23. The end cap of any one of claims 12 to 18, and 19 to 22 when dependent on any one of claims 12 to 18, wherein the web portions are formed to be deformable to accommodate predetermined variations in dimension of the end of an elongate member with which the 30 end cap is engageable.

24. A method of covering the end of an elongate member, the method including the step of placing an end cap according to any one of the preceding claims on an end portion of the elongate member. 35 300864915_1 .DOC 554190 16

25. The use of an end cap according to any one of claims 1 to 23 in covering an end portion of an elongate member.

26. An end cap substantially as herein described with particular reference to the Figures. Hi-Q Electronics Ltd By its Attorneys BALDWINS 300864915 1.DOC