Abstract
A connector system is provided for an apparatus intended to be walked on, swung on or jumped on in use. The connector system comprising a plurality of frame elements, each comprising an insertion portion, at least one protrusion, and frame element rotation reducing portions. Also provided is a plurality of first connector members, each configured to receive the insertion portion of at least one frame element into a channel therein. There are also a plurality of second connector members, each configured to mate with one first connector member, whereupon insertion of the insertion portion of at least one frame element into one first connector member, and mating of the one first connector member with one second connector member, the frame element cannot be removed from the first connector member due to the at least one protrusion of the frame element engaging with the second connector member; and the frame element is substantially unable to rotate in the first connector member due to the rotation reducing portions engaging with the channel of the first connector member.
Claims
1. A connector system for an apparatus intended to be walked on, swung on or jumped on in use, the connector system comprising a plurality of frame elements, each frame element comprising an insertion portion, at least one protrusion, and frame element rotation reducing portions; a plurality of first connector members, each first connector member configured to receive the insertion portion of at least one frame element into a channel therein; a plurality of second connector members, each second connector member configured to mate with one first connector member; whereupon insertion of the insertion portion of at least one frame element into one first connector member, and mating of the one first connector member with one second connector member; the frame element cannot be removed from the first connector member due to the at least one protrusion of the frame element engaging with the second connector member; and the frame element is substantially unable to rotate in the first connector member due to the rotation reducing portions engaging with the channel of the first connector member.
2. The connector system of claim 1, wherein the frame elements each have a longitudinal axis, and the rotation reducing portions comprise longitudinal splines, each longitudinal spline having a longitudinal axis substantially aligned with the longitudinal axis of the frame element, and wherein each longitudinal spline has a front wall and a rear wall, and the front wall of each longitudinal spline forms a series of protrusions thereby providing the at least one protrusion.
3. The connector system of claim 2, wherein there are at least 8 longitudinal splines.
4. The connector system of claim 1, wherein the at least one protrusion is a circumferential protrusion.
5. The connector system of any one of claim 1, wherein the at least one protrusion is integral with the insertion portion of the frame element.
6. The connector system of claim 1, wherein an inside wall of the channel of the first connector comprises first connector rotation reducing portions, wherein the first connector rotation reducing portions and the frame element rotation reducing portions engage with one another and are unable to pass over one another and thereby substantially prevent rotation.
7. The connector system of claim 1, wherein the second connector member mates with the first connector member by complementary screw threads on an outside wall of the first connector member and an inside wall of the second connector member.
8. The connector system of claim 7, configured to generate an aural indicator as the second connector member is screwed onto the first connector member.
9. The connector system of claim 8, wherein the first connector member comprises a series of teeth arranged around the periphery of an outside surface of the channel, and the second connector member comprises at least one ratchet arm, engageable with teeth during connection of the second connector member to the first connector member.
10. The connector system of claim 9, wherein the teeth are each sized and shaped to make a different pitch of sound as the ratchet arm moves over the teeth.
11. The connector system of claim 9, wherein the ratchet arm comprises a head that substantially prevents rotational movement of the second connector member in one direction once in place on the first connector member.
12. The connector system of claim 1, wherein the second connector member is provided in two half-parts which come together to form the second connector member.
13. The connector system of claim 12, wherein each half part of the connector comprises a part of a barrier wall which sandwiches the at least one protrusion between the first connector member and second connector member.
14. The connector system of claim 1, wherein the frame element is substantially circular in cross-section and the first connector member and the second connector member are each configured to receive frame elements being substantially circular in cross-section.
15. The connector system of claim 1, wherein the structure is rigid in the XY plane under application of 500 Newtons of force.
16. The connector system of claim 1, wherein each frame element is held about its entire outer periphery with substantially equal forces.
17. The connector system of claim 1, wherein each first and second connector member is formed from a plastic polymer and each frame element is metal.
18. An apparatus when connected by the connector system of claim 1.
19. A first connector member for use in the connector system of claim 1.
20. A kit for building playground apparatus, the kit comprising the following components, a plurality of frame elements according to claim 1; a plurality of first connector members according to claim 1; a plurality of second connector members according to claim 1; the components of the kit being provided with instructions on how to use the components in the connector system according to claim 1.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0085] Embodiments of the invention and other embodiments will now be described with reference to the accompanying drawings which are not drawn to scale and which are exemplary only and in which:
[0086] FIG. 1 is an embodiment of a frame element.
[0087] FIG. 2A and FIG. 2B are alternative embodiments of a frame element.
[0088] FIG. 3 is an embodiment of a connector part comprising two first connector members.
[0089] FIG. 4 shows alternative embodiments of connector parts.
[0090] FIG. 5A and FIG. 5B shows frame elements in the first connector members.
[0091] FIGS. 6A and 6B are connector parts for joining frame elements at right angles to one another.
[0092] FIG. 7A is a connector part for joining three frame elements. FIG. 7B shows a frame element being inserted into the channel of a first connector member. FIG. 7C shows the second connector member being applied to from the connector.
[0093] FIG. 8 is a close up of the inside of the channel of the first connector member of the connector part of FIG. 3.
[0094] FIG. 9 shows a sleeve (without frame element) inside of the first connector member.
[0095] FIG. 10 shows four embodiments of second connector members.
[0096] FIG. 11A is an alternative embodiment of a second connector member.
[0097] FIG. 11B is the second connector member of FIG. 11A when locked in position.
[0098] FIG. 12 is an embodiment of the first connector member and second connector member in which an alternative to screw threads is employed.
[0099] FIG. 13 is an embodiment in which the protrusions of the frame element interlock with the front wall of the first connector member.
[0100] FIG. 14 is an embodiment in which the rear wall is modified to interlock with the first end of the frame element.
[0101] FIG. 15 is an embodiment in which the frame element comprises an indentation, and a movable protrusion is provided in the channel of the first connector element.
[0102] FIG. 16 is an alternative view of the connector of FIG. 15.
[0103] FIG. 17 is an alternative embodiment in which the frame element comprises an indentation, and a movable protrusion is provided in the channel of the first connector element.
[0104] FIG. 18 is a perspective view of a frame element for insertion into the first connector member of FIG. 17.
[0105] FIG. 19 shows the first and second connector members relative to the frame element of FIG. 18.
[0106] FIG. 20 is an alternative embodiment in which the frame element comprises an indentation, and a movable protrusion is provided in the channel of the first connector element.
[0107] FIG. 21 shows the connector in place in a trampoline frame.
[0108] FIG. 22 is an alternative embodiment of the frame element for the connection system.
[0109] FIG. 23 is a side view of the frame element of FIG. 22 moving towards an movement of a first connector.
[0110] FIG. 24 is an alternative embodiment of a connection system.
[0111] FIG. 25 is an embodiment of a frame element.
[0112] FIG. 26 is an alternative view of an embodiment of the frame element.
[0113] FIG. 27 is an embodiment of a first connector showing inside the channel of one of the first connector members. The inset is a close up of the rotation reducing portion on the inside surface of the channel.
[0114] FIG. 28 is an alternative view of the first connector of FIG. 27.
[0115] FIG. 29 is a close up view of the frame element of FIG. 25 sliding into the first connector member of FIG. 27.
[0116] FIGS. 30 to 34 shown an embodiment of a second connector member provided in two half-parts. The second connector is disassembled in FIGS. 30 and 31 and assembled to form the second connector in FIGS. 32 to 24.
[0117] FIG. 35 is a top view of the second connector in place around the first connector (the frame element is removed for clarity). The inset shows a schematic cross-section of the teeth around the outside periphery of the first connector member.
[0118] FIG. 36 shows the connector according to an embodiment.
[0119] FIG. 37 is an embodiment of an in-line connector joining two frame elements.
[0120] FIG. 38 is an alternative embodiment of an in-line connector joining two frame elements.
[0121] FIG. 39 is an alternative embodiment of an insertion portion of a frame element.
[0122] FIG. 40 is an alternative embodiment of a first connector member.
[0123] FIG. 41 shows the frame element of FIG. 39 in the first connector member of FIG. 40.
[0124] FIGS. 42 and 43 show an alternative embodiment of a second connector provided in two half parts.
[0125] FIG. 44 is a cross sectional view of the connector of FIG. 41.
[0126] FIG. 45 is an embodiment of a connector showing how the second connector can dovetail with the body of the first connector.
[0127] FIGS. 46 to 46 show a proposed experimental set up for testing rigidity.
[0128] FIGS. 51 to 53 show the results of rigidity testing on an existing steel connector.
[0129] FIGS. 54 and 54 are simulated results of a frame element to frame element join.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0130] As can be seen in FIG. 1, an exemplary frame element 10 has an elongate body 12. The body 12 in this embodiment is straight. The body of the frame element 12 has a circular cross section. The elongate body 12 has a first end 14 and a second end 16. The first end 14 and the second end 16 are identical. The first end 14 of the frame element 12 can be for joining with the second end 16 of another, separate frame element 10 (see FIG. 5). The second end 16 of the frame element 10 can be for joining with the first end 14 of another, separate frame element 10 (not shown). In some embodiments, each end 14, 16 comprises an insertion portion A as described below. In other embodiments, one end 14 of the frame element 10 comprises a first connector member 24 and the other end 16 of the frame element 16 connector comprise an insertion portion A.
[0131] The end of the frame element 10 that will join with the connector 20 can have an insertion portion A. The insertion portion A is intended for insertion into the body 22 of the first connector 24.
[0132] In an embodiment, the insertion portion A can be delimited by one or more protrusions 26 around the frame element body 12. The function of the protrusion(s) 26 is to provide a part of the frame element 10 that can be gripped by the first connector 24 and second connector 30 members in use. The protrusion(s) around the outside of the frame element body 12 provide an area of increased diameter or increased cross sectional width for the frame element 10.
[0133] There can be one circumferential protrusion 26 as shown in FIG. 2A. In the case of a frame element 10 with a circular cross-section, the protrusion can be an annular ring 26. The ring is shown as a solid shape with squared edges. There can be a preference for solid edges to the protrusion 26, since the protrusion 26 will be properly sandwiched between the first connector member 24 and the second connector member 30 with all surfaces in contact with other surfaces. Since the function of the protrusion 26 is to provide an area of increased diameter on the body 12 of the frame element 10, the protrusion 26 does not have to be a solid ring as shown in FIG. 2A around the element body 12 and instead it can be provided in one or more parts as shown in FIG. 2B. Where the protrusions 26 are provided in parts, it can be referred to as a series of protrusions 26 around the outside periphery of the frame element 10. The series of protrusions 26 can be of any shape such as knobs, squared, rectangular columns, other. In FIG. 2B there are shown eight protrusions. In FIG. 39, each protrusion is the front end of a longitudinal spline.
[0134] The protrusions 26 can be provided on the frame element 10. In this embodiment, the frame element 10 is manufactured with the protrusion(s) 26 as shown in FIG. 2. Thus, the protrusions 26 are integral with the frame element 10 and cannot be removed from the frame element 10. Alternatively, the protrusions 26 are provided on an element that is attachable to the frame element 10. For example, the end 14, 16 of the frame element 10 could be capped with a sleeve 32 that has a part of it comprising one or more protrusions 26 around its outside periphery. The frame element 10 can be slid into the sleeve 32 and can be held by tight interference fit. To assist in gripping the frame element 10 into the sleeve 32 there can be a complementary shaped annular recess 34 for receiving the annular end wall 14, 16 of the frame element 10 therein (FIG. 9). In FIG. 9, the sleeve 32 is shown inserted into the first connector member 24, but the frame element 10 has been removed to show what the sleeve 32 looks like on the inside. In use, there would be a frame element in the sleeve 32. In some embodiments, sleeve 32 is screwed or otherwise affixed to frame element 10 as shown in e.g. FIG. 13.
[0135] Upon insertion of the insertion portion A of the frame element 10 into the connector 20, the first side 36 the protrusion 26 is facing forward towards the first connector 24. The second side 38 of the protrusion 26 is thus facing outwardly once the frame element 10 is engaged with the first connector 24.
[0136] The connector 20 comprises a first connector member 24 operable with a second connector member 30. Embodiments of a part of the connector 20 are shown in FIG. 3 and FIG. 4. In FIG. 3, the connector part has a body 22 with a first connector member 24 at one side and a first connector part 24 at the other side for joining two frame elements 10.
[0137] Each first connector member 24 comprises an outside surface 40 which is accessible and manipulatable. The first connector member has an inside surface 42 which is the wall defining the interior of a channel 44. The channel 44 in the first connector 24 is configured to allow insertion of the insertion portion A of the frame element 10. The channel 44 can be slightly wider than the insertion portion A of the frame element 10 to ensure that it can fit therein. In a preferred embodiment, the channel 44 is about the same diameter as the frame element 10 so as to allow a tight interference fit.
[0138] Once inserted into the channel 44, the frame element 10 may be able to rotate in the channel. In order to prevent or at least reduce any unwanted rotation, the inside surface wall 42 of the channel 44 can be modified with rotation reducing portions 46 to engage the frame element 10. The rotation reducing portions 46 can be ribs 48 in the channel wall 42 that are received into complementary recesses 50 provided on the frame element 10. As can be seen in FIG. 8, the ribs 48 and recesses 50 are arranged circumferentially around inside wall 42 of the channel 44 of the first connector member 24. The frame element 10 would thus be prevented from rotating in the channel 44 since the ribs would not allow for rotational movement. FIG. 1 shows the complementary shaped rotation reducing portions 46 provided on a sleeve 32. The complementary shaped ribs 48 and recesses 50 slide over one another to prevent rotation. It should be understood that any shaping of the inside wall 42 of the channel and the frame element 10 (or associated sleeve 32) could be provided.
[0139] The channel 44 has an opening 52 through which the insertion portion A of the frame element 10 is received. The opening 52 can be defined by a front wall 54 of the channel 44 which can be a rim around the front of the first connector member 24. The front wall 54 at the forward part of the first connector member 24 can have a smooth flat surface which in some embodiments can be for engagement with the first surface 36 of the protrusion 26 or series of protrusions 26.
[0140] Upon insertion of the frame element 10 into the channel 44, the protrusion 26 or series of protrusions 26 can abut against the front wall 54 as shown in e.g. FIG. 5A providing a natural stop for further insertion movement of the frame element 10 into the channel 44. In embodiments, the front wall 54 can be modified so as to dovetail with the protrusion 26 which has a complementary shape to interlock with the front wall 54 (e.g. FIG. 13). This interlocking of the protrusion 26 and front wall 54 can prevent any rotational movement of the frame element 10 once inserted into channel 44 of the first connector 24. The channel 44 also have a rear wall 56. The first end 14 of the frame element 10 may or may not abut the rear wall 56 prior to the direct contact between the first 36 surface of the protrusions 26 or series of protrusions 26, and the front wall 54 of the first connector member 24. In embodiments, the rear wall 56 can be modified so as to interlock with the first end 14 of the insertion portion of the frame element 10, so as to further prevent any rotational movement of the frame element 10 once inserted. The interlocking can be by a lock and key type of complementary shaping which in FIG. 14 is shown as a star-shaped key 56 which sits into a complementary shaped lock on the first end 14 of frame element 10 (not shown). The lock and key can be reversed such that the lock part is on the rear wall while the key is provided on the frame element. The contact of the complementary shapes being received in lock and key arrangement can prevent rotation of the frame element 10 in channel 44.
[0141] The rear wall 56 can be a solid wall at the rear of the channel 44. The rear wall can be an annular wall 56. The rear wall 56 need only be sufficient to stop advancement of the frame element 10 through the channel 44 of the first connector 24. The rear wall 56 is shown in FIG. 8 as a barrier at the rear of the channel 44. In some embodiments, upon insertion of the insertion portion A of the frame element 10 into the channel 44, the first end 14 of the frame element 10 abuts the rear wall 56 of the channel 44 before the protrusion 26 or series of protrusions 26 contact with the front wall 54. In this embodiment, the rear wall 56 provides a natural stop for further insertion movement of the frame element 10. This is shown in e.g. FIG. 5B. In this embodiment, there will be a gap G between the front wall 54 and the protrusion 26 or series of protrusions 26. The gap G will eventually be covered by the second connector member 30 and should not affect the overall structural integrity of the connector system. FIG. 41 also shows that an embodiment in which the rear wall 456 provides a stop for the advancing frame element 410. In this embodiment, the protrusion will never prevent advancing movement into the channel 444 and instead the rear wall 456 is required as the stop.
[0142] In order to complete the connector 20, the second connector member 30 is brought into contact with the first connector member 24. In FIG. 7B and FIG. 7C the direction of the movement of the second connector member 30 is shown by arrows. In an embodiment, the forward wall of the second connector member 30 can interlock with wall 19 of the first connector member 24. This is also shown in FIG. 46.
[0143] FIG. 10 shows a variety of second connector members 30. In an embodiment, as shown in FIG. 11, the second connector member 30 is in two or more parts 31 and 33 and it is assembled around the first connector member 24. The second connector member 30 can be in parts that are hingedly (or otherwise) connected to one another and which can be clamped around the first connector member 24 and then locked into position. The second connector member 30 can have an open position as shown in FIG. 11A which can receive the first connector member 24; and a closed, locked position as shown in FIG. 11B in which the second connector member 30 is locked around the first connector member 24.
[0144] To lock the second connector member 30 that comes in a plurality of parts into place around the first connector member 24, there can be a locking mechanism 60. The locking mechanism can comprise screws, hook and tab or other. Once in place, the second connector member 30 provides a barrier wall 62 that abuts the second side 38 of the circumferential protrusion 26 or series of protrusions 26. The barrier wall 62 thereby prevents any removing movement of the frame element 10 from the channel 44 of the first connector member 24. The barrier wall 62 can be provided as one continuous wall covering the second side 38 of the circumferential protrusion 26 or series of protrusions 26. The barrier wall could also be provided in separate wall parts. provided that the circumferential protrusion 26 or series of protrusions 26 abut against it and their movement is barred.
[0145] In an embodiment, the second connector member 30 is in one part as shown in FIG. 10. When the second connector member 30 is in one part, it is necessary that it has a passageway 64 therethrough to receive the frame element 10. The second connector member 30 can be slid over the frame element 10 and brought towards the insertion portion A inside the channel 44 of the first connector member 24. Once in place around the first connector member 24, the second connector member 30 provides a barrier wall 62 that abuts the second side 38 of the circumferential protrusion 26 or series of protrusions 26. The barrier wall 62 thereby prevents any removing movement of the frame element 10 from the channel 44 of the first connector member 24.
[0146] The second connection member 30 comprises a connection assembly 70 associated with the barrier wall 62 that is configured to engage the second connector member 30 to the first connector 24 member so that the barrier wall 62 is able to act as a barrier. The function of the connection assembly 70 is to prevent unintentional disengagement of the barrier wall 62 from the first connector 24. The connection assembly 70 can be any means that reversibly connects the second connection member 30 to the first connection member 24. In an embodiment, the connection assembly 70 is a series of complementary ribs and recess (or protrusions and apertures; or like) on the outside wall 40 of the first connector member 24 and the inside wall 72 of the second connector member 30 that are complementary shapes and which upon engagement cause the first connector member 24 and the second connector member 30 to be interlocked together to prevent disengagement of the second connector member 30. FIG. 12 shows the arrangement with ribs 74 and recesses 76 on outside wall 40. The complementary shaped ribs 74 and recesses 76 on inside wall 72 of the second connector member 30 cannot be seen.
[0147] The connection assembly 70 as shown can also prevent any rotational movement of the second connector member 30 relative to the first connection member 24 when locked into position. The connection assembly 70 can operate together with the locking mechanism 60 on the second connector member 30 to reversibly engage the first connector member 24 and second connector member 30 to one another.
[0148] In an embodiment, complementary ribs 74 and recesses 76 on the outside wall of 40 the first connector member 24 and the inside wall 72 of the second connector member 30 forming the connection assembly 70 come in the form of screw threads. In this embodiment, as shown in the Figures the second connector member 30 can be screwed onto the first connector member 24 to be interlocked.
[0149] As the second connector member is screwed onto the first connector member 24 in a first direction (see FIG. 7), the barrier wall 62 moves closer to the circumferential protrusion 26 or series of protrusions 26. When the barrier wall 62 abuts the second side 38 of the protrusion 26 or series of protrusions 26 (or the first end 14 of the frame element 10 hits rear wall 56 of channel 44), the second connector member 30 can be given one last tightening turn and then it substantially remains in position. The second connector member 30 can be turned in a second direction that is opposite to the first direction to remove or disengage it from the first connector member 24. When the second connector member 30 is required to be removed from the first connector member 24, it can be turned in the second direction until the barrier wall 62 is moved away from the circumferential protrusion 26 or series of protrusions and the threads disengage 26.
[0150] To assist in applying the second connector member 30 to the first connector member 24 in embodiments, the outside wall 73 of the second connector member can be modified with a gripping surface 78 (FIG. 10). The gripping surface can include one or more gripping ridges 78 that allow for purchase to be applied to the second connector member 30 to force it into position.
[0151] To indicate to the user when the second connector member 30 is in location such that the protrusion 26 or series of protrusions 26 is/are sandwiched between the first connector member 24 and the second connector member 30 there can be provided an indicator 80. In an embodiment, the indicator 80 is a click sound that is made when the barrier wall 62 of the second connector member 30 engages with the front wall 54 of the first connector member 24. In FIG. 13, the indicator 80 is shown as protrusions 82 which click with recesses 84 on the protrusion 26. FIG. 46 shows lower profile protrusions that connect with complementary shaped indentations.
[0152] FIG. 6 is a right-angled connector which allows the connection of frame elements at right angles to one another. Any variation of angle can be accommodated by modification of the connector. A passageway P is also provided through the connector which allows for a further frame element to be joined to the connected frame elements. FIG. 7 is a three-way connector which allows for the joining of three frame elements into each of the channels 44 of the connector. FIG. 21 shows the connector 100 in place joining the frame elements 10 of a trampoline.
[0153] In an embodiment, the insertion portion A of the frame element 10 has an indentation 80 on the frame element body 12. The function of the indentation 80 is to provide a part of the frame element that can be gripped by the first connector 24 in use. As insertion portion A slides into the channel 44 of first connector 24 (as shown in FIGS. 15 and 16), protrusion 82 provided on the side wall of channel 44. The user grips protrusion mover 84 which comprises a spring-loaded pin biased towards the protracted or engaged position as shown in FIG. 15. Upon pulling the pin upwards against the bias pressure, the protrusion 82 is removable from the channel space and into the wall of the first connector 24. In this retracted position, there is room for the frame element 10 to be inserted. When the user relieves the pressure on protrusion mover 84, and the protrusion 82 is released back into the channel, the protrusion 82 is aligned with indentation 80. The protrusion 82 engages with the indentation 80 and thereby prevents unwanted removal of the frame element 10 from the channel 44. For additional structural stability in use, a second connector 30 can then be located over the first connector element 24 in the same way as described above. As can be seen in FIG. 16, the connection assembly 70 allowing the first connection element 24 and second connection element 30 to mate can be screw threads.
[0154] FIGS. 17A and 17B show an alternative embodiment in which the protrusion 80 is an annulus 82 movable out from the channel 44 of the first connector by application of pressure onto protrusion mover 84. When the user applies pressure to protrusion mover 84 as shown in FIG. 17A, the insertion portion A of frame element 10 can be pushed all the way into the channel 44 until the first end 14 of the frame element 10 engages with the rear wall 56. As can be seen in FIG. 17A, the rear wall is modified with a star-shaped key 56 which sits into a complementary shaped lock 56 on the first end 14 of frame element 10 (see FIG. 18). As can be seen in FIG. 19, as the frame element 10 is inserted into the first connector 24, second connector 30 can be moved into position.
[0155] In the embodiment shown in FIG. 20, there is shown an embodiment in which the protrusion 82 is also spring biased; however, in this embodiment, rather than the protrusion 82 being spring biased into the channel 44 of the first connector member, the protrusion 82 is spring biased out of the channel 44. As sleeve 84 is manually moved in the direction of the arrow shown in FIG. 20, the protrusion 82 is able to relax and extend into the wider aperture 85 of the sleeve 84. In this retracted position, the frame element 10 can be inserted. Once inserted, the sleeve 84 retraction can be released, and the sleeve 84 forces protrusion 82 into the indention 80 which aligns with it in the channel. There is no second connector 30 in this embodiment, although one could be used if desired.
[0156] In an embodiment, frame element 110 has an elongate body 112. The end of the frame element 110 that will join with the connector 120 can have an insertion portion A. The insertion portion A is intended for insertion into the body 120 of the first connector 144. As shown in FIG. 23, the channel 144 inside the first connector 120 can be provided by an insert 121 that slides into a tube D to form the first connector 120. To join the insert 121 with the tube D and prevent unwanted movement of it out of the tube D during use, the tube D and connector insert 121 can be crimped together or otherwise fastened (not shown).
[0157] In some embodiments, where the connector is for a tube to tube in a longitudinal line, the front wall 154 of the connector 120 can be modified with at least one gripper 190. There can be any number of grippers 190 arranged around the circumference of the front wall 154. In an embodiment there are eight grippers 190 (only four can be seen in FIG. 23). A plurality of narrow grippers 190 can provide improved flexibility over fewer wider grippers 190. Each of the grippers 190 can be configured to engage with the protrusion 126 provided on the frame element 110. When sliding into the channel 144, the protrusions 126 can slide under the finger like grippers 190 which will engage and grip the protrusion. Once grippers 190 are locked over the protrusion 126, it should be understood that removal of the frame element 110 from the channel 144 of the first connector 120 would be difficult unless each of the gripper 190 fingers is lifted off the protrusion 136 to release it. Effectively, the grippers 190 prevent the frame element 110 from being unwantedly withdrawn from the first connector 120.
[0158] In this embodiment of FIG. 23, the second connector member 130 is a collar that can be passed over the grippers that have engaged with the protrusion 126. The second connector member 130 thereby ensures that the grippers 190 are held into the gripped position and ensure that the grippers 190 are unable to release their gripping forces. The collar 130 can be held in place by frictional forces or other locking mechanism. To release the connector system, the collar 130 can be disengaged, the grippers 190 can be released from protrusions 126 (manually or using tools) and then the frame element 110 can be withdrawn from connector 120.
[0159] FIG. 24 shows an embodiment in which the frame element 210 that will join with the connector 220 has an insertion portion A. The insertion portion A is intended for insertion into the body 220 of the first connector 244. Once inserted, the second connector member 230 can be locked into position by engagement of the connection assembly being a quarter turn screw thread 253 with complementary features on the inside surface of second connector member 230 and outside wall of connector 244. In order to further prevent unintended removal of the second connector member 230 once in position, there can be tabs 255 which snap into the second connector member 230. These tabs can function as protrusions 226. The tabs 255 can be sandwiched between the first connector member and the second connector member, wherein the rod or tube 210 cannot be removed from the connection system until the second member 230 is disengaged from the first connector member 220.
[0160] In another embodiment, insertion portion A is received in first connector 424 and then collar 430 is secured around the joined frame elements 410, 410 with protrusion 426 sandwiched between them. A turn of the second connector 430 will secured it in place (FIG. 37). In FIG. 38 there is shown another embodiment in which a clip 599 can be pressed over second connector 530 to secure it into place.
[0161] Turning now to FIG. 25, there is shown a frame element 310 with a body 312. The end of the frame element 310 that will join with the connector can have an insertion portion A. The insertion portion A is intended for insertion into the body of the first connector 324. The insertion portion A can be integral with the body 312. The insertion portion A can have a smaller diameter to the remainder of the elongate body 312 of the frame element. This can be useful where the insertion portion slides into the first connector member and is secured into position by a second connector member where the outside surfaces of the elongate body of the frame element and second connector member can be substantially flush with one another as shown in e.g. FIG. 36.
[0162] In FIG. 25, it can be seen that there is one circumferential protrusion 326. The protrusion 326 is accompanied by longitudinal splines 348 that extend along the longitudinal length of the insertion portion A. These splines 348 can assist with decreasing rotation of the frame element 310 once inserted into the first connector 324, if there are complementary ribs inside the channel 344 of the first connector 324.
[0163] An embodiment in which there are a plurality of longitudinal splines 448 around the outside periphery of the insertion portion A is shown in FIG. 39. Each spline 448 is shown formed in one single piece. The spline 448 is formed across about 85% of the distance of the insertion portion A with a land where the barrier wall 462 will eventually be located. Each spline 448 is shown having an elongate axis substantially aligned with the longitudinal axis of the frame element.
[0164] Also shown in FIG. 39 is that the end of insertion portion A can be capped with a capping button 427.
[0165] There are eight splines 448 provided around the periphery of the insertion portion A. Each spline has a first longitudinal side 448 and a second longitudinal side 448. Each spline has a forward end 436. When the insertion portion A of the frame element 410 is inserted into the first connector member 424 the spline 448 can slide into a channel formed in the inside surface of the first connector member 424. Each channel in the first connector member can be formed from longitudinal ribs 446. Each rib 446 can have a first side and a second side. The first side of the rib 446 can abut with the first longitudinal side of a spline 448 and the two are unable to pass over one another. This means that rotational forces applied to the frame element 410 are absorbed by the splines 448 and ribs 446 and the frame element 410 is prevented or substantially reduced from rotating inside the first connector member 424.
[0166] Turning back to FIG. 25, the diameter of the frame element is about 3.5 cm (measured from outside wall to outside wall). The diameter of the frame element (measured from outside edge of protrusion 326 to outside edge of protrusion 326) is increased to about 3.9 cm by the protrusions (about 10%).
[0167] As shown in FIG. 26, the protrusion 326 comprises a first side 336 and a second opposing side 338. Upon insertion of the insertion portion A of the frame element 310 into the connector 324, the first side 336 of the protrusions 326 is facing forward towards the first connector 324. The second side 338 of the protrusions 326 is thus facing outwardly once the frame element 310 is engaged with the first connector 324.
[0168] The connector 320 of the present invention comprises a first connector member 324 operable with a second connector member 330. The first connector member 324 comprises an outside surface. The first connector member has an inside surface which is the wall defining the interior of a channel 344.
[0169] The channel 344 in the first connector 324 is configured to allow insertion of the insertion portion A of the frame element 310. The channel 344 can be slightly wider than the insertion portion A of the frame element 310 to ensure that it can fit therein. In a preferred embodiment, the channel 344 is about the same diameter as the frame element 310 so as to allow a tight interference fit. Once inserted into the channel 344, the frame element 310, may be able to rotate in the channel. In order to prevent or at least reduce any unwanted rotation, the inside surface of the channel 344 is modified with rotation reducing portions 346 to engage the frame element 310. As seen in FIG. 27, the rotation reducing portions 346 can be ribs 348 in the channel wall that are received into complementary recesses 350 provided on the frame element 310. The frame element 310 would thus be prevented from rotating in the channel 344 since the ribs 348 would not allow for rotational movement.
[0170] The rotation reducing portions 346, 348 on the inside wall of the channel 344 of the first connector 324 can each have a top surface 347, a rear end wall (not seen) near the back of the channel 344, and a forward end wall 349 near the opening 352 of the channel 344. The top surface 347 of the first connector rotation reducing portion 346 can be narrow as shown in FIG. 27. There are about sixteen first connector rotation reducing portions 346 in FIG. 27. The space between each first member rotation reducing portion (or between pairs of them) can be referred to as a channel 351.
[0171] The channel 344 has an opening 352 through which the insertion portion A of the frame element 310 is received. The opening 352 can be defined by a front wall 354 of the channel 344 which can be a rim 354 around the front of the first connector member 324. The front wall 354 at the forward part of the first connector 324 can have a smooth flat surface which in some embodiments can be for engagement with the first surface 336 of the protrusion 326. In some embodiments, the front wall 354 of the first connector 324 comprises the forward end walls 349 of any rotation reducing portions 346 provided in the channel 344. Therefore, the front wall 354 can be the rim 354 around the front of the first connector 324; the forward end walls 349 of any rotation reducing portions 346 provided in the channel 344; or both provided together 354, 349. Upon insertion of the frame element 310 into the opening 352, the protrusion 326 can abut against the forward walls 349 of the rotation reducing portions as shown in FIG. 29. The protrusion 326 thereby provides a natural stop for further insertion movement of the frame element 310 into the channel 344.
[0172] In order to complete the connector 320, the second connector member 330 is brought into contact with the first connector member 324. In an embodiment, the second connector member 330 is in two parts 330a and 330b and it is assembled around the first connector member 324. The second connector member 330 can be in parts that can be clamped around the first connector member 324 and then locked into position. The second connector member 324 can have an open position (FIGS. 30 and 31) which can receive the first connector member 324 and a closed, locked position (FIGS. 32, 33, 34) in which the second connector member 330 can be locked around the first connector member 324 (although in FIGS. 32-34 the second connector member 330 is shown separate to the first connector member 324).
[0173] As shown in the FIGS. 30-34, the second connector comprises two half-parts 330a, 330b. First half-part 330a and a second half-part 330b are identical to one another. Once the second half-part 330b is inverted with respect to the first part 330a, the two half-parts together provide the second connector member 330. Each half part 330a, 330b, can have first joining side X and a second joining side Y. A catch 331 can be provided on each half-part at the first joining side X, the catches 331a and 331b can provide a recess (shown as a rectangular hole in FIG. 31). A boss 333 can be provided on each half part at the second joining side Y, the bosses 333a, 333b can be locatable into the recesses of the respective catches 331a, 331b. When the two half-parts 330a 330b are brought together, the respective catches 331a 331b can locate the respective bosses 333a 333b and the two half parts 330a 330b are held securely together around the first connector member 324b. A tool may be required to separate the parts once connected. The tool can be used to prise up the catch 331 and remove it from the boss 333.
[0174] In an alternative embodiment, the two half parts 430a, 430b are not identical as shown in FIG. 44. This can be advantageous for making sure that the two half parts are connected in the correct way. As shown in the FIGS. 43 and 44, the second connector can comprise two half-parts 430a, 430b. First half-part 430a and a second half-part 430b are different to one another in that 430a has the bosses 433 and 430b has the catches 431a, 431b. When the two half-parts 430a 430b are brought together, the respective catches 431a 431b can locate the respective bosses 433a 433b and the two half parts 430a 430b are held securely together around the first connector member 424b. A tool may be required to separate the parts once connected. The tool can be used to prise up the catch 431 and remove it from the boss 433.
[0175] Once in place, in an embodiment, the second connector member 330 can provide a barrier wall 362 that abuts the second side 338 of the protrusion 326 of the insertion portion A. The barrier wall 362 thereby prevents any removing movement of the frame element 310 from the channel 344 of the first connector member 324. The barrier wall 362 is provided in separate wall parts 362a and 362b as seen in FIG. 34. A first barrier wall part 362a is on half-part 330b and a second barrier wall part 362b is on provided on half-part 330b. The barrier wall 462 is provided in separate wall parts 462a and 462b as seen in FIG. 44.
[0176] The second connector member 330 comprises a connection assembly 370. The connection assembly 370 is associated with the barrier wall in that it is integral with it. The connection assembly 370 is configured to engage the second connector member 330 to the first connector member 324. In an embodiment shown the connection assembly 370 comprises complementary ribs and recesses on the outside wall of the first connector member 324 and the inside wall of the second connector member 330 in the form of screw threads. There is a complementary screw thread on the first connector 324 (see FIG. 27). The function of the connection assembly is to prevent unintentional disengagement of the second connection member 330 from the first connection member 324. As the second connector member 330 is screwed onto the first connector member 324 in a first direction, the barrier wall 362 moves closer to the protrusion 326. When the barrier wall 362 abuts the second side 328 of the protrusion 326, the second connector member 330 can be given one last tightening turn and then it substantially remains in position. The second connector member 330 can be turned in a second direction that is opposite to the first direction to remove or disengage it from the first connector member 324. When the second connector member 330 is required to be removed from the first connector member 324, it can be turned in the second direction until the barrier wall 362 is moved away from the protrusion 326 and the threads disengage.
[0177] In an embodiment, as the connection assembly 370 is formed by screwing the complementary screw threads 370, 370 to one another, there is an aural indicator (sound) of the joining process. This can be provided by at least one ratchet arm 390 provided in the second connector body 330. The flexible ratchet arm 390 is biased to a position flush with the second connector body wall 330, but the ratchet arm 390 can be lifted if a head part 392 of the ratchet arm 390 is forced outwardly from the wall of the second connector 330. A top view of the ratchet arm 390 and its head part 390 can be seen in FIG. 35. In FIG. 35 the insertion portion is removed from the channel 344 of first connector 324 so the inside of the mechanism can be seen more clearly. The ratchet arm 390 engages with teeth 394 arranged in formation around the forward peripheral edge of the outside wall of the first connector 324. The teeth can be seen in FIG. 35 and quite clearly in FIG. 28.
[0178] The ratchet arm 390 is located on the second connector member 330 body such that it engages with a tooth 394 of the first connector member 324 just prior to the threading process. As the second connector member 330 is screwed onto the first connector 324, the ratchet arm 390 rises over the tooth body 394 and then falls onto the next tooth 394 in series. Advantageously, in embodiments in which there is one row of teeth, the ratchet arm 390 is sized relative to the teeth 394 so that it engages with them over more than one turn. Alternatively, there can be more than one row of teeth in a spiral formation that complements the turning circle of the ratchet arm 390. Nevertheless, the sequential connection of the ratchet arm 390 with the teeth 394 in the series makes a sound each time the head part 392 of the ratchet arm 392 falls to another tooth 394. Over a few turns of the second connector 330 relative to the first connector 324 in the direction of the arrows shown in FIG. 35 there can be a loud and pleasing mechanical sound that allows the user to at once know that the first and second connectors are securely joined, and that the join is as tight as possible since the noise stops. An additional advantage of the ratchet arm 390 is that once the first connector 324 and the second connector 330 are joined, they are unable to come loose relative to one another because the head part 392 of the ratchet arm 390 prevents an unscrewing motion. The head part 392 of the ratchet arm 390 abuts the preceding tooth 394 and will not allow rotational movement in the direction opposite to the arrows shown in FIG. 35.
[0179] The number of the teeth 394a, 394b, 394c and the size of the head part 392 of the ratchet arm 390 will contribute to the loudness and frequency of the aural indicator. In an embodiment shown in which the diameter of the first connector 324 is about 3.5 cm there are about 32 teeth around the outside periphery of the opening. Each tooth 394 can have a slope portion 396 over which the head part 392 of the ratchet arm 390 moves in a forward screwing direction S. Each tooth 394 also has a stop portion 398. As the head 392 of the ratchet arm 390 falls off the end of the slope portion 396 of a first tooth 394a, the head part 392 of the ratchet arm 390 can fit into the gap defined by the slope portion 396 of a second tooth 394b and the stop portion 398 of the adjacent first tooth 394b (triangular shaped). The stop portion 398 of any one tooth 394 prevents rotational movement in the unscrewing direction (opposite to arrow S), since the head 392 of the ratchet arm 390 cannot move past the stop portion 398 in the unscrewing direction. In an embodiment, the slope portion 396 of each tooth 394 and the stop portion 398 of each tooth 394 is the same dimension as shown in FIG. 35. This means that each tooth 394 provides for the same tone of sound as an aural indicator. In an alternative embodiment, the slope portion 396 and the stop portions 398 of each tooth 394 are different angles, lengths and or heights, which makes a different sound for each tooth as the ratchet head 392 moves over each different tooth 294d, 394e, 394f. By varying the teeth and therefore by changing the corresponding sound emitted a tune can be created. The three teeth shown in FIG. 35 will make only three decreasing notes, but it should be understood that with 20 or 30+ teeth over 1, 2 or 3 turning circles a whole melody could be created.
[0180] FIG. 36 shows the second connector 330 in place with the first connector 324 with the protrusion (not seen) sandwiched between. Frame element 310 cannot be removed from the connector 320.
[0181] The second connector member 430 also comprises a connection assembly 470. In an embodiment, the connection assembly 470 is formed by screw threads 470 and 470. To join the first connector 424 to the second connector 430, the user can screw the complementary screw threads 474, 476 to one another, there is an aural indicator (sound) of the joining process. This can be provided by at least one ratchet arm in the form of a thin fin 490 provided in the second connector body half parts 430a and 430b. The ratchet arm 490 engages with teeth 494 arranged in formation around the forward peripheral edge of the outside wall of the first connector 424. The teeth 494 can be seen in FIGS. 40 and 41.
[0182] FIG. 45 is a cross-sectional view of the connector once assembled. Upon insertion of the insertion portion A of the frame element A into the first connector member 424, and mating of the first connector member 424 with the second connector member 430, the frame element 410 cannot be removed from the first connector member 424 due to the protrusion 426 of the frame element 410 engaging with the second connector member 430; and the frame element 410 is substantially unable to rotate in the first connector member 424 due to the rotation reducing portions 448 engaging with the channel 44 of the first connector member 424.
Experimental Testing
[0183] Embodiments of the invention will now be described with reference to the following none limiting examples.
[0184] The connector of embodiments of the present invention provides more rigidity than prior connectors. In order to quantify rigidity, the following experiment was undertaken. [0185] Construct a testing frame capable of fixing a connector and/or frame element with join [0186] Insert test frame element, fixed length at 1000 mm, and secure into first connector as intended. [0187] Apply force (n), force to be determined, along the XY plane in direction A. [0188] Apply force (n), force to be determined, along the XY plane in direction B [0189] Measure total deflection (d). Deflection (d)=Rigidity
Results
Experiment: Cast Steel Joiner Rigidity (Comparative Testing with Existing Metal Connector)
Test Environment Set Up:
[0190] Fixed cast steel joiner housed in testing apparatus [0191] 48.3 mm2.0 mm steel tube inserted into joiner [0192] 100 newton force applied to end of length (l) [0193] 500 newton force applied to end of length (l)
[0194] At resting state in the testing apparatus, the steel tube measured 15 mm from the straight edge (FIG. 51). With 100 newtons of force applied along the XY plane, the steel tube shows 42 mm of deflection from the straight edge (FIG. 52). With 500 newtons of force applied along the XY plane, the steel tube shows 170 mm of deflection from the straight edge (FIG. 53). In conclusion, it is evident that the current cast steel joiner that secures the tube using a grub screw shows a significant amount of deflection from its resting position when both a force of 100 newtons and 500 newtons is applied.
Experiment: Present Connector Simulation
[0195] It is prophesised that the present connector will have increased rigidity to the existing metal connector. It is hypothesised that the amount of deflection will be substantially less under the same test circumstances.
[0196] Simulated results on the frame element to frame element connection (with the connector joining two frame elements as shown in FIGS. 54 and 55) show that with a force of 500N (50 kg) applied on the XY plane, a predicted deflection of 29 mm from its original state.
[0197] It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
[0198] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word comprise or variations such as comprises or comprising is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
[0199] Any promises made in the present description should be understood to relate to some embodiments of the invention and are not intended to be promises made about the invention as a whole. Where there are promises that are deemed to apply to all embodiments of the invention, the applicant/patentee reserves the right to later delete them from the description and does not rely on these promises for the acceptance or subsequent grant of a patent in any country.
