AU2011202217A1 - A Safety Cap - Google Patents

Abstract

-13 Abstract A safety cap 20, 70 for placing on an exposed end of an elongate post or reinforcing bar is disclosed. The safety cap 20, 70 includes a hollow body 21, and a strap 22 for securing the body 21 to an object such as, for example, the 5 elongate post or reinforcing bar. 43 o54

Description

rl/UUfU I I 40/0/0 I Regulation 3.2 AUSTRALIA Patents Act 1990 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Name of Applicant: Phillip Graham Calow Actual Inventor Phillip Graham Calow Address for service is: WRAYS Ground Floor, 56 Ord Street West Perth WA 6005 Attorney code: WR Invention Title: A SAFETY CAP The following statement is a full description of this invention, including the best method of performing it known to me:- -2 A SAFETY CAP Field of the Invention The present invention relates generally to a safety cap and, in particular 5 to a safety cap for use as a cap or guard fitted on an exposed or protruding end of a steel star picket which may form part of a fence or barricade, and also for use as a cap or guard fitted over the end of an exposed reinforcing bar of a concrete structure during its construction. 10 Background Art Typically, the exposed ends of star picket posts and protruding reinforcing bars (known as starter bars in concrete construction) have been covered by a simple push on safety cap to protect persons from injury. One known safety cap includes a side wall, a hollow centre, a closed 15 end, an open end, and a plurality of engagement vanes extending from the side wall into the centre. The vanes are flaps which extend from the closed end to the open end in parallel to the longitudinal axis of the cap. The vanes are connected to both the side walls and the closed end. The vanes flex apart to allow for engagement with different shapes and sizes of reinforcing bar or elongate post. 20 Once a bar or post has been inserted into a safety cap, the vanes press against the sides of the bar or post. The traditionally used caps, such as the cap described above, which are injection molded plastic caps have proven to become easily disengaged/dislodged from the ends of star pickets and reinforcing bars when 25 brushed against allowing the potentially dangerous end of the star picket or reinforcing bar to be exposed. The star pickets and bars generally have sharp edges on their exposed ends. These sharp edges are often in the form of burrs which are produced by hammering the star pickets in to the ground or by cutting the star pickets or 30 reinforcing bars. These sharp edges can be dangerous and covering them with a safety cap is able to prevent them from injuring someone. It is against this background that the present invention has been developed.

-3 Summary of the Invention It is an object of the present invention to overcome, or at least ameliorate, one or more of the deficiencies of the prior art mentioned above, or to provide the consumer with a useful or commercial choice. 5 Other objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, a preferred embodiment of the present invention is disclosed. According to a first broad aspect of the present invention, there is 10 provided a safety cap for placing on an exposed end of an elongate post or reinforcing bar, the safety cap including a hollow body, and a strap for securing the body to an object. The strap may be used to secure the body to a variety of objects. For example, the strap may be used to secure the body to the elongate post or 15 reinforcing bar so that the body is inhibited from coming off the exposed end of the post or bar. Alternatively, the strap may be used to secure the body to an object other than the object (e.g. post or reinforcing bar) whose end the safety cap has been placed. For example, the strap may be used to secure the body to safety barricade mesh. The strap may be passed through that other object (e.g. 20 safety barricade mesh) and may then be secured to the object (e.g. post or reinforcing rod) whose end the safety cap has been placed. Preferably, the hollow body includes a side wall, a hollow centre, a closed end, an open end, and a plurality of engagement vanes extending from the side wall in to the centre. Preferably, the hollow body has a substantially 25 triangular-shaped profile. Preferably, the engagement vanes also extend from the closed end of the hollow body. Preferably, the strap includes at least one formation, and the safety cap also includes at least one first opening for engaging with the at least one formation so as to secure an end portion of the strap relative to the cap. In a 30 preferred embodiment, each at least one formation is an enlarged portion, and each first opening includes a first portion through which the enlarged portion is able to be inserted through, a second portion through which the enlarged portion is unable to be withdrawn through, and a third portion which is able to allow the strap to be moved from the first portion to the second portion, and which is able -4 to inhibit the strap from being moved from the second portion to the first portion. It is preferred that the strap includes a plurality of the enlarged portions and that the enlarged portions are spaced apart from each other along the strap. Preferably, at least some of the enlarged portions are domed cylindrical-shaped 5 or triangular cone-shaped. In a first particular preferred form, the body includes each one of the first openings. In a second particular preferred form, the strap includes each one of the first openings. In a third particular preferred form, the body and the strap each include a respective one of the first openings. Preferably, each of the first openings in the strap is in a respective one of the 10 enlarged portions of the strap. In another preferred embodiment, each at least one formation is in the form of a series of teeth/gears, and each first opening includes a ratchet for engaging with one or more of the teeth/gears. In a particular preferred form, the strap is in the form of a ratchet-type tie such as, for example, a cable tie which 15 includes the series of teeth/gears, and the first opening including the ratchet. Preferably, the strap is formed integrally with the hollow body. For example, if the safety cap is fabricated by a molding process (e.g. an injection molding process), the strap is preferably integrally molded with the hollow body. Preferably, the safety cap also includes at least one frangible anchor 20 which secures the strap to the body. Preferably, a tip of the strap includes a grip for a person to hold on to when breaking the at least one frangible anchor by pulling on the strap. It is preferred that the grip is in the form of a series of teeth. Preferably, the side wall includes a plurality of second openings. The 25 second openings are preferably aligned with each other. According to a second broad aspect of the present invention, there is provided an assembly including a safety cap according to the first broad aspect of the present invention, and a first object including an end, wherein the hollow body of the safety cap is placed on the end of the first object, and the strap of the 30 safety cap is secured to one of the first object and a second object. Preferably, the first object is selected from a group comprising: a post; and a bar. According to a third broad aspect of the present invention, there is provided a method for securing a safety cap according to the first broad aspect of -5 the present invention relative to a first object including an end, the method comprising the steps of: placing the hollow body of the safety cap on the end of the first object; and 5 securing the strap of the safety cap to one of the first object and a second object. Brief Description of the Drawings In order that the invention may be more fully understood and put into 10 practice, a preferred embodiment thereof will now be described with reference to the accompanying drawings, in which: Figure 1 is a top view of a first safety cap embodiment of the present invention; Figure 2 is a side view of the safety cap illustrated in figure 1; 15 Figure 3 is a bottom view of the safety cap illustrated in figure 1; Figure 4 is a side view of a second safety cap; Figure 5 is a side view of the safety cap illustrated in figure 4 after the frangible anchors which secure the cap's strap to the cap's body have been broken; 20 Figure 6 depicts the body of the safety cap illustrated in figure 4 placed on an exposed end of a star picket and secured to the star picket with the cap's strap; and Figure 7 depicts the body of the safety cap illustrated in figure 4 placed on an exposed end of a reinforcing bar and secured to the reinforcing bar with 25 the cap's strap. Best Mode(s) for Carrying out the Invention In the figures, like features have been referenced with like reference numerals. 30 Referring to figures 1 to 3, there is depicted a first safety cap 20. Safety cap 20 is for placing on an exposed end of an elongate star picket-type post, reinforcing bar, or other object. Safety cap 20 is able to protect persons from being injured by the sharp exposed end of the star picket, reinforcing bar, or other object which it is placed on. Safety cap 20 includes a hollow body 21, and -6 an elongate flexible strap 22 which is integrally molded with the body 21. Strap 22 extends from the body 21 and is for securing the body 21 relative to an object. Body 21 has a substantially triangular-shaped profile and includes a side wall 23, a hollow centre 24, a closed end 25, an open end 26, and a plurality of 5 engagement vanes 27 which extend from the side wall 23 and the closed end 25 in to the centre 24. Vanes 27 extend in to the centre 24 such that a gap 28 separates an edge 29 of each vane 27 from a face 30 of an adjacent vane 27, and such that the vanes 27 define a central socket 31. The hollow centre 24, gaps 28, and socket 31 are dimensioned so that an exposed end of a star picket 10 (not depicted) is able to be inserted into the socket 31 such that each laterally extending formation of the picket which gives the picket a three-pointed star shaped profile extends through a respective one of the gaps 28, and so that the vanes 27 press firmly against the formations and thereby inhibit the picket from being withdrawn from the socket 31. Moreover, the socket 31 is dimensioned so 15 that an exposed end of a reinforcing bar (not depicted) is able to be inserted into the socket 31 such that the vanes 27 press firmly against the bar and inhibit the bar from being withdrawn from the socket 31. Strap 22 is approximately 20 centimetres long and includes a first end 40 which is secured to the side wall 23 of the cap body 21, and a second end 41. 20 Strap 22 also includes a plurality of domed cylindrical-shaped enlarged portions 42 and an enlarged portion 43. The enlarged portions 42, 43 are spaced apart from each other along the length of the strap 22. A tip 44 of the strap 22 includes a series of teeth 45 which are able to function as a grip for a person to hold on to with their fingers. Strap 22 is secured to the side wall 23 of the cap body 21 by a 25 plurality of frangible anchors 46 which extend from the enlarged portions 42, 43 and tip 44 to the side wall 23. Strap 22 is secured to the cap body 21 such that the strap 22 surrounds the side wall 23 and is located adjacent to the open end 26 of the cap body 21. Anchors 46 can be broken so that the strap 22 is partially detached from the cap body 21 by a person grasping the grip formed by 30 the teeth 45 with their fingers and then pulling on the strap 22 with sufficient force to break the anchors 46. The closed end 25 of the cap body 21, and the enlarged portion 43 of the strap 22 each include a first opening 50 for securing an end portion 51 of the strap 22 relative to the safety cap 20. Each first opening 50 includes a first -7 portion 52 through which the enlarged portions 42, 43 are able to be inserted, a second portion 53 through which the enlarged portions 42, 43 are unable to be withdrawn through, and a third portion 54 which is able to allow the strap 22 to be moved from the first portion 52 to the second portion 53, and which is able to 5 inhibit the strap 22 from being moved from the second portion 53 to the first portion 52. Strap 22 can be used to secure the cap body 21 to a variety of objects. For example, if the safety cap 20 is placed on an exposed end of a star picket such that the star picket is received by the socket 31 and such that the 10 formations of the star picket which give the picket a three-pointed star-shaped profile extend through the gaps 28, the strap 22 can be used to further secure the cap 20 to the picket. To do this, the frangible anchors 46 are firstly broken so that the strap 22 is only secured to the cap body 21 at its first end 40. The end portion 51 of the strap 22 is then inserted into one of the first openings 50. In 15 particular, the end portion 51 is inserted through the first portion 52 of the first opening 50 so that at least one of the enlarged portions 42 and/or the enlarged portion 43 (if the end portion 51 is inserted through into the first opening 50 in the closed end 25) is inserted through the first portion 52. Once a sufficient amount of the end portion 51 of the strap 22 has been inserted through the first portion 20 52, the strap 22 is then moved from the first portion 52 of the first opening 50 to the second portion 53 of the first opening 50 through the narrow third portion 54 of the first opening 50 so that the enlarged portion 42 or the enlarged portion 43 which has been inserted through the first portion 52 and which is closest to the first opening 50 is prevented from being withdrawn from the first opening 50. 25 Preventing the enlarged portion 42 or the enlarged portion 53 which has been inserted through the first portion 52 and which is closest to the first opening 50 from being withdrawn from the first opening 50 prevents the end portion 51 of the strap 22 from being withdrawn from the first opening 50 so that the strap 22 thereby secures the cap body 21 to the star picket and prevents the safety cap 30 20 from being dislodged from the exposed end of the star picket and falling to the ground where it may potentially be damaged or lost. The reverse procedure can be used to detach the strap 22 from the picket. In particular, the strap 22 is moved from the second portion 53 of the first opening 50 to the first portion 52 of the first opening 50 through the third portion -8 54 of the first opening 50. After this has been done, the end portion 51 of the strap 22 can then be withdrawn from the first opening 50 through the first portion 52. A similar procedure to that described above can be used to secure the 5 cap body 21 to other objects. For example, a similar procedure may be used to secure the cap body 21 to safety barricade mesh. Referring to figure 4, there is depicted a second safety cap 70. Safety cap 70 is identical to the safety cap 20 except that the side wall 23 of the safety cap 70 includes three rectangular-shaped second openings 71 which are aligned 10 with each other. Second openings 71 can be used to secure the safety cap 70 relative to another object. For example, if the safety cap 70 is placed on an exposed end of a star picket in a manner similar to that described above in relation to the safety cap 20 such that the second openings 71 are aligned with one or more openings in the picket; the safety cap 70 may be secured to the 15 picket by wire (for example) which is inserted through one or more of the second openings 71 and one or more of the openings in the picket. In figure 5, the strap 22 of the safety cap 70 is depicted after the frangible anchors 46 which secured the strap 22 to the side wall 23 of the cap body 21 have been broken so that only the first end 40 of the strap 22 is secured 20 to the side wall 23. Figure 6 depicts the safety cap 70 placed on an exposed end of a star picket 80. Strap 22 of the cap 70 has been partially detached from the cap body 21 by breaking the frangible anchors 46. The end portion 51 of the strap 22 has then been inserted through an opening 81 in the picket 80. The end portion 51 25 has then been inserted through the first opening 50 in the enlarged portion 43 so that some of the enlarged portions 42 have been inserted through the first portion 52 of the opening 50. The strap 22 has then been moved from the first portion 52 to the second portion 53 through the third portion 54 so that the enlarged portion 42 which has been inserted through the first portion 52 and which is 30 closest to the enlarged portion 43 is inhibited from being withdrawn through the opening 50. In this way, the cap body 21 has been secured to the picket 80 by the strap 22. The safety cap 70 and the star picket 80 when the safety cap 70 is mounted on and secured relative to the star picket 80 in the manner described -9 comprises an assembly 81. Figure 7 depicts the safety cap 70 placed on an exposed end of a reinforcing bar 90. The cap body 21 has been secured to the bar 90 in a similar manner to the way the cap 70 was secured to the picket 80 in figure 6, except 5 the strap 22 is merely trained around the bar 90 which does not have any openings within reach of the strap 22 that the strap 22 may be inserted through. The safety cap 70 and the reinforcing bar 90 when the safety cap 70 is mounted on and secured relative to the reinforcing bar 90 in the manner described comprises an assembly 91. 10 Safety caps 20, 70 are manufactured from an injection moldable plastic using an injection molding manufacturing process. For example, the safety caps 20, 70 may be manufactured from polyethylene, polypropylene, or other Olefin. Preferably, the first end 40 of the strap 22 of the safety caps 20, 70 is secured to the side wall 23 of the cap body 21 by a filleted joint (not depicted) to 15 provide a strong connection. Instead of the enlarged portions 42 being domed cylindrical-shaped, those portions 42 may be triangular cone-shaped barbs (not depicted). It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing 20 from the spirit and scope thereof. The variations and modifications as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth. Throughout the specification and claims, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", 25 will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. Throughout the specification and claims, unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms. 30 It will be clearly understood that, if a prior art publication is referred to herein, that reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country,

Claims (27)

1. A safety cap for placing on an exposed end of an elongate post or reinforcing bar, the safety cap including a hollow body, and a strap for securing the body to an object. 5

2. The safety cap defined by claim 1, wherein the hollow body includes a side wall, a hollow centre, a closed end, and open end, and a plurality of engagement vanes extending from the side wall in to the centre.

3. The safety cap defined by claim 2, wherein the hollow body has a substantially triangular-shaped profile. 10

4. The safety cap defined by claim 2 or 3, wherein the engagement vanes also extend from the closed end of the hollow body.

5. The safety cap defined by any one of the preceding claims, wherein the strap includes at least one formation, and the safety cap also includes at least one first opening for engaging with the at least one formation so as to secure an 15 end portion of the strap relative to the cap.

6. The safety cap defined by claim 5, wherein each at least one formation is an enlarged portion, and each first opening includes a first portion through which the enlarged portion is able to be inserted through, a second portion through which the enlarged portion is unable to be withdrawn through, and a third portion 20 which is able to allow the strap to be moved from the first portion to the second portion, and which is able to inhibit the strap from being moved from the second portion to the first portion.

7. The safety cap defined by claim 6, wherein the strap includes a plurality of the enlarged portions, and wherein the enlarged portions are spaced apart 25 from each other along the strap.

8. The safety cap defined by claim 6 or 7, wherein at least some of the enlarged portions have a domed cylindrical-shape.

9. The safety cap defined by claim 6 or 7, wherein at least some of the enlarged portions have a triangular cone-shape. 30

10. The safety cap defined by any one of claims 5 to 9, wherein the body includes each one of the first openings.

11. The safety cap defined by any one of claims 5 to 9, wherein the strap includes each one of the first openings. - 11

12. The safety cap defined by any one of claims 5 to 9, wherein the body and the strap each include a respective one of the first openings.

13. The safety cap defined by claim 11 or 12, wherein each of the first openings in the strap is in a respective one of the enlarged portions of the strap. 5

14. The safety cap defined by claim 5, wherein each at least one formation is in the form of a series of teeth/gears, and each first opening includes a ratchet for engaging with one or more of the teeth/gears.

15. The safety cap defined by claim 14, wherein strap is in the form of a ratchet-type tie which includes the series of teeth/gears, and wherein the first 10 opening includes the ratchet.

16. The safety cap defined by any one of the preceding claims, wherein the strap is formed integrally with the hollow body.

17. The safety cap defined by any one of the preceding claims, wherein the safety cap also includes at least one frangible anchor which secures the strap to 15 the body.

18. The safety cap defined by claim 17, wherein a tip of the strap includes a grip for a person to hold on to when breaking the at least one frangible anchor by pulling on the strap.

19. The safety cap defined by claim 18, wherein the grip is in the form of a 20 series of teeth.

20. The safety cap defined by any one of claims 2 to 19, wherein the side wall includes a plurality of second openings.

21. The safety cap defined by claim 20, wherein the second openings are aligned with each other. 25

22. An assembly including a safety cap defined by any one of the preceding claims, and a first object including an end, wherein the hollow body of the safety cap is placed on the end of the first object, and the strap of the safety cap is secured to one of the first object and a second object.

23. The assembly defined by claim 22, wherein the first object is selected 30 from a group comprising: a post; and a bar.

24. A method for securing a safety cap defined by any one of claims 1 to 21 relative to a first object including an end, the method comprising the steps of: placing the hollow body of the safety cap on the end of the first object; and - 12 securing the strap of the safety cap to one of the first object and a second object.

25. A safety cap substantially as hereinbefore described with reference to: figures 1 to 3; or figures 4 to 7. 5

26. An assembly substantially as hereinbefore described with reference to: figure 6; or figure 7.

27. A method for securing a safety cap, the method being substantially as hereinbefore described with reference to: figure 6; or figure 7.