U.S. patent application number 15/499583 was filed with the patent office on 2017-11-02 for magnetized reinforcing bar protective cap.
The applicant listed for this patent is ZL Innovations, Inc.. Invention is credited to Eileen M. Butler, Alyssa J.L. Caganda, Carlos A. Fuentes, Anahis A. Kechejian, Matthew G. Lesher, Caleb J. Linn, Lawrence F. Zorio, III.
Application Number | 20170314270 15/499583 |
Document ID | / |
Family ID | 60158158 |
Filed Date | 2017-11-02 |
United States Patent
Application |
20170314270 |
Kind Code |
A1 |
Zorio, III; Lawrence F. ; et
al. |
November 2, 2017 |
MAGNETIZED REINFORCING BAR PROTECTIVE CAP
Abstract
A protective cap for covering an exposed end of any sized
reinforcing bar (rebar or reinforced steel) is provided. The
protective cap is configured to be affixed to an exposed end of the
reinforcing bar and protect falling objects from being punctured by
the reinforcing bar. The protective cap includes a magnet embedded
and secured within the protective cap to secure the protective cap
to the reinforcing bar.
Inventors: |
Zorio, III; Lawrence F.;
(Billerica, MA) ; Linn; Caleb J.; (Keene, NH)
; Lesher; Matthew G.; (Lewes, DE) ; Caganda;
Alyssa J.L.; (Boston, MA) ; Fuentes; Carlos A.;
(Boston, MA) ; Kechejian; Anahis A.; (Arlington,
MA) ; Butler; Eileen M.; (Fremont, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ZL Innovations, Inc. |
Billerica |
MA |
US |
|
|
Family ID: |
60158158 |
Appl. No.: |
15/499583 |
Filed: |
April 27, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62328359 |
Apr 27, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04C 5/161 20130101 |
International
Class: |
E04C 5/16 20060101
E04C005/16 |
Claims
1. A protective cap, comprising: a cap top end and a cap bottom end
opposite the top end; a crumple zone structure located within the
protective cap proximal the cap top end, the crumple zone structure
configured to withstand a force resulting from a maximum weight of
two-hundred and fifty pounds dropped from a maximum height of ten
feet above the protective cap; a collar structure located at the
cap bottom end, the collar structure sized and dimensioned to fit
over and receive an end section of reinforcing bar in such a way
that the protective cap surrounds and removably couples with the
end section of reinforcing bar; and a magnetic field located
internally within the protective cap at a top end of the collar
structure; wherein the protective cap is comprised of two halves
that are mechanically coupled together to form the protective
cap.
2. The protective cap of claim 1, wherein the two halves comprise:
a first cap half having a first cap half top end and a first cap
half bottom end, the first cap half comprising: a first half of the
crumple zone structure located at the first cap half top end; a
first half of the collar structure located at the first cap half
bottom end; and a first plurality of mechanically interconnecting
features configured for mechanical coupling with a second plurality
of mechanically interconnecting features; a second cap half having
a second cap half top end and a second cap half bottom end, the
second cap half comprising: a second half of the crumple zone
structure located at the second cap half top end; a second half of
the collar structure located at the second cap half bottom end; and
the second plurality of mechanically interconnecting features
configured for mechanical coupling with the first plurality of
mechanically interconnecting features; wherein the first cap half
mechanically couples with the second cap half by the first
plurality of mechanically interconnecting features interconnecting
with the second plurality of interconnecting features to form the
protective cap.
3. The protective cap of claim 1, wherein the magnetic field is
generated from a plurality of magnetic particles integrated into
the protective cap structure.
4. The protective cap of claim 1, wherein the magnetic field is
generated from a magnet or magnetized component located in an
internal chamber of the protective cap at a top end of the collar
structure.
5. The protective cap of claim 1, wherein the magnetic field is
generated from neodymium or ferrite.
6. The protective cap of claim 1, wherein when the protective cap
is removably coupled with an end section of reinforcing bar the
magnetic field interacts with the reinforcing bar to magnetically
pull the protective cap against the reinforcing bar, contributing
to holding the protective cap in place.
7. The protective cap of claim 1, wherein the crumple zone
structure comprises a plurality of crumple zones.
8. The protective cap of claim 1, wherein the force resulting from
the weight of two-hundred and fifty pounds dropped from the height
of up to ten feet above the protective cap matches a level required
to withstand OSHA mandated load conditions without failure.
9. The protective cap of claim 1, wherein the protective cap is
manufactured of injection molded High Density Polyethylene
(HDPE).
10. The protective cap of claim 1, wherein the collar structure
sized and dimensioned to fit over and receive an end section of
reinforcing bar in such a way that the protective cap removably
couples with the end section of reinforcing bar comprised of
different sizes.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority to, and the benefit of,
co-pending U.S. Provisional Application No. 62/328,359, filed Apr.
27, 2016, for all subject matter common to both applications. The
disclosure of said provisional application is hereby incorporated
by reference in its entirety.
FIELD OF THE INVENTION
[0002] This present invention relates to the field of workplace and
personal safety. The invention relates to protection of individuals
from impalement hazards, and other injuries that exist from exposed
ends of reinforcing steel bars (otherwise known as "rebar") onto
and into which individuals could fall. More specifically, the
invention relates to a protection cap configured for placement on
exposed ends of reinforcing bar and having a magnetic field aiding
in the coupling of the protection cap with the reinforcing bar by
action of the attractive magnetic force between the protection cap
and the reinforcing bar.
BACKGROUND
[0003] Generally, the Occupational Safety and Health Administration
(OSHA) requires that all protruding reinforcing steel, onto and
into which employees could fall, be guarded to eliminate the hazard
of impalement. OSHA considers devices (covers or wooden troughs)
that are capable of withstanding at least two-hundred and fifty
pounds dropped from a height of ten feet to be adequate to meet the
.sctn.1926.701(b) rebar requirements. There are devices known for
protecting against impalement hazards created by exposed ends of
reinforcing steel that meet OSHA's guidelines. These devices
include impact resistant troughs or caps made of, or a combination
of, metal, plastic, or wood. The trough or cap is placed over the
impalement hazard(s) and secured in place by mechanically gripping
the reinforcing steel. Unfortunately, protection systems that
utilize a gripping mechanism are prone to frequent dislodging
and/or falling off due to accidental contact from individuals
and/or vibration of the reinforcing steel or other environmental
factors. When these systems become dislodged or fall off,
individuals are no longer protected from the impalement hazard, and
the worksite is in violation of the OSHA requirements.
[0004] Existing protection systems rely on the individual
installing the system to properly install, physically monitor, and
re-install the system when it becomes dislodged or falls off. A
shortcoming with these types of systems is that there is no
automated monitoring system integrated that can provide alerts
if/when the system is no longer secured to the impalement hazard.
As such, these systems rely on constant post installation
inspection to identify if impalement hazards exist. The, delay or
absence of a post installation inspection can mean the existence of
a life threatening hazard that goes unnoticed for long periods of
time. Additionally, the failure of these caps to stay secure on
reinforcing bar can result in safety citations (fines) and/or
temporary shutdown of worksites.
SUMMARY
[0005] There is a need for improved reinforcing bar capping
technology to avoid the above-noted shortcomings and issues related
to conventional capping systems and devices. The present invention
is directed toward further solutions to address this need, in
addition to having other desirable characteristics. Specifically,
the present invention includes a protective cap with collar
designed to be affixed to exposed ends of reinforcing bar (e.g.,
reinforcing steel or rebar) and not experience the dislodging
characteristics of conventional rebar caps. The present invention
provides a protective cap structure comprised of two half caps
mechanically coupled together, assembled with a magnetic field
generating element positioned to magnetically couple the protective
cap with the reinforcing bar, thus improving the coupling of the
protective cap with the reinforcing bar over conventional systems.
Additionally, the inventive protective cap includes a structural
crumple zone in an upper portion of the cap that can absorb a force
of a maximum of two-hundred and fifty pounds dropped from a maximum
height of ten feet onto the cap positioned on the reinforcing bar
without the reinforcing bar poking through the protective cap. As
noted, the cap of the present invention includes a magnetic field
generating element, which can be implemented as, e.g., a magnetized
steel plate, magnet, and/or magnet injected plastic mold, to secure
the cap to exposed reinforcing bar. As a result, the magnetized cap
is less susceptible to becoming dislodged or displaced through
physical contact, vibration, weather, or traditional wear and tear,
than conventional protection caps. The cap can be reused and
maintain its effectiveness to affix to reinforcing steel and is
equally effective in the vertical or horizontal position.
[0006] In accordance with example embodiments of the present
invention, reinforced cap is provided. The protective cap includes
a cap top end and a cap bottom end opposite the top end and a
crumple zone structure located within the protective cap proximal
the cap top end. The crumple zone structure is configured to
withstand a force resulting from a maximum weight of two-hundred
and fifty pounds dropped from a maximum height of ten feet above
the protective cap. The protective cap also includes a collar
structure located at the cap bottom end. The collar structure is
sized and dimensioned to fit over and receive an end section of
reinforcing bar in such a way that the protective cap surrounds and
removably couples with the end section of reinforcing bar. The
protective cap further includes a magnetic field located internally
within the protective cap at a top end of the collar structure.
Additionally, the protective cap is constructed from two halves
that are mechanically coupled together to form the protective
cap.
[0007] In accordance with aspects of the present invention, the two
halves include a first cap half having a first cap half top end and
a first cap half bottom end. The first cap half includes a first
half of the crumple zone structure located at the first cap half
top end, a first half of the collar structure located at the first
cap half bottom end, and a first plurality of mechanically
interconnecting features configured for mechanical coupling with a
second plurality of mechanically interconnecting features. The two
halves also includes a second cap half having a second cap half top
end and a second cap half bottom end. The second cap half includes
a second half of the crumple zone structure located at the second
cap half top end, the second half of the collar structure located
at the second cap half bottom end, and the second plurality of
mechanically interconnecting features configured for mechanical
coupling with the first plurality of mechanically interconnecting
features. The first cap half mechanically couples with the second
cap half by the first plurality of mechanically interconnecting
features interconnecting with the second plurality of
interconnecting features to form the protective cap.
[0008] In accordance with aspects of the invention, the magnetic
field can be generated from a plurality of magnetic particles
integrated into the protective cap structure. The magnetic field
can be generated from a magnet or magnetized component located in
an internal chamber of the protective cap at a top end of the
collar structure. The magnetic field can be generated from
neodymium, ferrite, or other similar operable magnet. When the
protective cap is removably coupled with an end section of
reinforcing bar, the magnetic field interacts with the reinforcing
bar to magnetically pull the protective cap against the reinforcing
bar, contributing to holding the protective cap in place.
[0009] In accordance with aspects of the invention, the crumple
zone structure comprises a plurality of crumple zones. The force
resulting from the weight of two-hundred and fifty pounds dropped
from the height of up to ten feet above the protective cap matches
a level required to withstand OSHA mandated load conditions without
failure.
[0010] In accordance with aspects of the invention, the protective
cap is manufactured of injection molded High Density Polyethylene
(HDPE), or other similar operable material.
[0011] In accordance with aspects of the invention, the collar
structure sized and dimensioned to fit over and receive an end
section of reinforcing bar in such a way that the protective cap
removably couples with the end section of reinforcing bar comprised
of different sizes.
BRIEF DESCRIPTION OF THE FIGURES
[0012] These and other characteristics of the present invention
will be more fully understood by reference to the following
detailed description in conjunction with the attached drawings, in
which:
[0013] FIG. 1 is an illustrative perspective view of the protective
cap in accordance with the present invention;
[0014] FIG. 2 is an illustrative perspective view of the protective
cap in accordance with the present invention;
[0015] FIG. 3 is an illustrative cross-sectional view of the
protective cap, in accordance with the present invention; and
[0016] FIGS. 4A, 4B, and 4Cs are illustrative perspective views of
cap halves that form the protective cap, in accordance with the
present invention.
DETAILED DESCRIPTION
[0017] An illustrative embodiment of the present invention relates
to a magnetized protective cap for placement on exposed ends of any
sized reinforcing bar to protect workers from potential injury
caused by falling on exposed reinforcing bar. In particular, the
present invention provides a protective cap made up of two
mechanically fitting half caps coupled together, forming the
protective cap and encasing a magnetic field or magnetic field
generating material. The protective cap is designed to removeably
slide over an end of exposed reinforcing bar with the magnetic
field or magnetic field generating material being adjacent to the
end of the reinforcing bar, sufficiently close to enable magnetic
attractive forces to additionally hold the protective cap onto the
reinforcing bar. The configuration and inclusion of the magnetic
field or magnetic field generating material within the protective
cap provides a mechanism to firmly secure the protective cap to the
reinforcing bar through a combination of friction fit and magnetic
attraction forces (e.g., the magnetism from the cap attracting to
the metal properties of the reinforcing bar).
[0018] The protective cap also includes a crumple zone structure
designed to withstand Occupational Safety and Health Administration
(OSHA) mandated load conditions. Specifically, the crumple zones
provide by the protective cap are designed to withstand a force
generated by a maximum of two-hundred and fifty pound object
falling from a maximum height of ten feet without the reinforcing
protective cap failing and the reinforcing bar poking through the
cap. It will be appreciated that the invention is equally
applicable to any steel protrusion, or similar structure, that
requires impalement protection pursuant to the Occupational Safety
and Health Administration (OSHA) requirement that all protruding
reinforcing steel, onto and into which employees could fall, be
guarded by the protective cap of the present invention to eliminate
the hazard of impalement.
[0019] Referring to the figures, wherein like numerals indicate
like or corresponding parts throughout the several views, a
magnetically affixed protective cap is generally shown. For
purposes of illustration and not to be in any way limiting, the
following description will make reference to the magnetically
affixed protective cap on reinforcing bar. As would be appreciated
by one skilled in the art, the protective cap can include
alternative options for magnetizing including a magnet, magnetized
steel plate, and/or magnet injected plastic mold. In accordance
with an example embodiment of the present invention,
[0020] FIGS. 1 through 4C, wherein like parts are designated by
like reference numerals throughout, illustrate an example
embodiment or embodiments of an improved protective cap for
placement on exposed reinforcing bar, according to the present
invention. Although the present invention will be described with
reference to the example embodiment or embodiments illustrated in
the figures, it should be understood that many alternative forms
can embody the present invention. One of skill in the art will
additionally appreciate different ways to alter the parameters of
the embodiment(s) disclosed, such as the size, shape, or type of
elements or materials, in a manner still in keeping with the spirit
and scope of the present invention.
[0021] FIGS. 1-4C depict example embodiments of a protective cap
100. The overall structure of the protective cap 100 includes a cap
top end 102 and a cap bottom end 104 positioned opposite the cap
top end 102. The protective cap 100 also includes a combination of
features created by the cap top end 102, the cap bottom end 104 and
the area in between the cap ends 102, 104. For example, the cap top
end 102 can be a rectangular design, as depicted in FIGS. 1, 3, and
4A-4C, or a circular design, as depicted in FIG. 2, while
maintaining the required functional features of the protective cap
100 as described throughout herein. Accordingly, regardless of
shape and dimension, the protective cap 100 includes a combination
of features to provide the utility of the protective cap 100. An
exemplary utility feature of the protective cap 100 includes the
protective cap 100 fitting on an end of a reinforcing bar to
provide a protective structure for objects that may fall on the
otherwise exposed reinforcing bar. The protective cap 100 of the
present invention provides a combination of structural elements
that enable the protective properties. In particular, the
protective cap 100 includes magnetic field to more effectively
secure the protective cap 100 on an end of the reinforcing bar and
a crumple zone structure 106 designed to absorb impact of objects
dropped on the reinforcing bar end.
[0022] In accordance with an example embodiment of the present
invention, the crumple zone structure 106 is located within the
protective cap 100 proximal the cap top end 102. In particular, the
protective cap 100 includes one or more cavities or crumple zones
within the cap top end 102, as depicted in FIGS. 3 and 4A, designed
to absorb an impact of an object falling on top of the protective
cap 100. In accordance with an example embodiment of the present
invention, the crumple zone structure 106 is configured to
withstand a force resulting from a maximum weight of two-hundred
and fifty pounds dropped from a maximum height of up to ten feet
above the protective cap 100 (e.g., a level required to withstand
Occupational Safety and Health Administration (OSHA) mandated load
conditions) without failure. As would be appreciated by one skilled
in the art, the crumple zone structure 106 can include a single
crumple zone or a plurality of crumple zones configured to handle
such an impact. For example, the crumple zone structure 106 can
include a plurality of rectangular crumple zones as depicted in
FIGS. 3 and 4A. Additionally, although FIGS. 3 and 4A depict a
plurality of rectangular crumple zones, the present invention is
not intended to be limited to this implementation, such that the
crumple zone structure 106 can be constructed from any combination
crumple zones of different shapes and dimensions without departing
from the scope of the present invention.
[0023] In accordance with an example embodiment of the present
invention, the protective cap 100 further includes a collar
structure 108 located at the cap bottom end 104. The collar
structure 108 is sized and dimensioned to fit over and receive an
end section of reinforcing bar 110 in such a way that the
protective cap 100 fits over, surrounds, and removably couples with
the end section of reinforcing bar 110, as depicted in FIGS. 2 and
3. For example, the collar structure 108 can include a cylindrical
cavity 108c designed to slide over and form a friction fit around
an end section of reinforcing bar 110. As would be appreciated by
one skilled in the art, different sized and dimensioned protective
caps 100, and included collar structure 108, can be created for
different sized and shaped reinforced bar or other exposed building
materials.
[0024] In addition to the crumple zone structure 106, the
protective cap 100 can include other structural features designed
to improve strength and force absorption of the protective cap 100.
For example, the protective cap 100 can include a plurality of
trusses 112 connecting the cap top end 102 and the cap bottom end
104 to improve the strength of the overall protective cap 100
structure. In an example embodiment, the trusses 112 are attached
to an underside of the cap top end 102 and the external sides of
the collar structure 108. The trusses 112 can contribute to the
structural integrity of the protective cap 100 required to resist
impact without failure.
[0025] Additionally, in accordance with an example embodiment of
the present invention, the protective cap 100 includes a magnetic
field or magnetic field generating material 114 located internally
within the protective cap 100 to increase a level of security of
the protective cap 100 to the end section of reinforcing bar 110.
The magnetic field generating material 114 is positioned at a top
end of the collar structure 108, as depicted in FIGS. 2, 3, and 4A,
adjacent to the location of where an end section of reinforcing bar
110 ends up when the protective cap 100 is placed thereon, as
depicted in FIGS. 2 and 3. In accordance with an example embodiment
of the present invention, the magnetic field is generated from a
plurality of magnetic particles integrated into the protective cap
100 structure or a magnetic field generating material 114 (e.g., a
magnetic plate) located in an internal chamber of the protective
cap 100. For example, the magnetic field generating material 114
can be ferrite, neodymium, or other magnetic material known in the
art integrated within the protective cap 100. With the magnetic
field generating material 114 included within the protective cap
100, when the protective cap 100 is removably coupled with an end
section of reinforcing bar 110 the magnetic field interacts with
the reinforcing bar 110 to magnetically pull the protective cap 100
toward the reinforcing bar 110, contributing to the additional
available forces (e.g., gravity, friction, magnetism, etc.) holding
the protective cap 100 in place on the end section of reinforcing
bar 110. As would be appreciated by one skilled in the art, the
magnetic field generating material 114 can include any combination
of substances capable of generating a magnetic force to attract the
protective cap 100 to an end section of reinforcing bar 110,
including but not limited to a magnet, magnetic particles,
magnetized metal, or the like.
[0026] In accordance with an example embodiment of the present
invention, the protective cap 100 is constructed from two cap
halves 100a, 100b that are mechanically coupled together to form
the protective cap 100. The two cap halves 100a, 100b include a
first cap half 100a having a first cap half top end 102a and a
first cap half bottom end 104a. The first cap half 100a also
includes a first half of the crumple zone structure 106a located at
the first cap half top end 102a and a first half of the collar
structure 108 located at the first cap half bottom end 104a. The
first cap half 100a further includes placement for the magnetic
field generating material 114. For example, the first cap half 100a
can include a first cavity portion 114a for insertion of a magnet
or a first magnetically embedded portion 114b including magnetic
particles. Additionally, in accordance with an example embodiment
of the present invention, the first cap half 100a includes a first
plurality of mechanically interconnecting features 116a configured
for mechanical coupling with a second plurality of mechanically
interconnecting features 116b.
[0027] The protective cap 100 also includes a second cap half 100a.
Similar to the first cap half 100a, the second cap half 100b has a
second cap half top end 102b and a second cap half bottom end 104b.
The second cap half 100b also includes a second half of the crumple
zone structure 106b located at the second cap half top end 102b and
a second half of the collar structure 108b located at the second
cap half bottom end 104b. The second cap half 100b further includes
placement for the magnetic field generating material 114. For
example, the second cap half 100b can include a second cavity
portion 114b for insertion of a magnet or a second magnetically
embedded portion 114b including magnetic particles. Additionally,
in accordance with an example embodiment of the present invention,
the second cap half 100b includes the second plurality of
mechanically interconnecting features 116b configured for
mechanical coupling with the first plurality of mechanically
interconnecting features 116a.
[0028] To form the protective cap 100, the first cap half 100a
mechanically couples with the second cap half 100b by the first
plurality of mechanically interconnecting features 116a
interconnecting with the second plurality of interconnecting
features 116b. As would be appreciated by one skilled in the art,
the mechanically interconnecting features 116a, 116b can include
any mechanical arrangement configured to form the two cap halves
100a, 100b into a single protective cap 100. For example, the
mechanically interconnecting features 116a, 116b can include a
plurality of tabs configured for inserting into a plurality of
slots to form a friction fit, or a snap fit, between the first cap
half 100a and the second cap half 100b. Additionally, although the
discussion of the two cap halves 100a, 100b provide examples of
mechanical coupling with mechanically interconnecting features
116a, 116b, that can be undone (e.g., are removably coupled
together) as would be appreciated by one skilled in the art, the
two cap halves 100a, 100b could be joined utilizing any method
known in the art. For example, in an alternative embodiment, the
two cap halves 100a, 100b could be joined together by plastic
welding or other technique without the reliance on mechanically
tabs or slots.
[0029] In accordance with an example embodiment of the present
invention, when the two cap halves 100a, 100b are joined to form
the protective cap 100 they combine to form the features of the
protective cap 100 as discussed herein. In particular, the joined
two cap halves 100a, 100b will form the cap top end 102 (e.g.,
formed from the first cap half top end 102a and the second cap half
top end 102b) the cap bottom end 104 (e.g., formed from the first
cap half bottom end 104a and the second cap half bottom end 104b),
the crumple zone structure 106 (e.g., formed from the first crumple
zone structure 106a and the second crumple zone structure 106b),
the collar structure (e.g., formed from the first collar structure
108a and the second collar structure 108b), and the magnetic field
generating material 114 (e.g., via a cavity portion for insertion
of a magnet or embedded magnetic portion),
[0030] In accordance with an example embodiment of the present
invention, the protective cap 100 is manufactured of injection
molded High Density Polyethylene (HDPE). As would be appreciated by
one skilled in the art, the protective cap 100 can be constructed
from any combination of materials utilizing any combination of
manufacturing techniques. For example, the protective cap 100 can
be printed utilizing three-dimensional printing techniques or any
other technique known in the art.
[0031] FIGS. 1-4C depict various illustrative views of the
protective cap 100 and the various components that make up the
protective cap 100. FIG. 1 depicts an example illustrative view of
the completely assembled protective cap 100. In particular, FIG. 1
depicts the protective cap 100 as a single piece, or as provided in
an example embodiment, two cap halves 100a, 100b joined together to
form a single piece. The protective cap 100, as depicted in FIG. 1,
includes the cap top end 102 including the crumple zone structure
106, the cap bottom end 104 including the collar structure 108 with
cap top end 102 fixedly attached to the cap bottom end 104. FIG. 1
also depicts the plurality of trusses 112 connected to the cap top
end 102 and the cap bottom end 104, providing additional structural
integrity to the protective cap 100. The collar structure 108
includes the cylindrical cavity 108c configured to receive an end
section of a reinforcing bar 110. A magnetic field generating
material 114 is included at the end of the collar structure 108
proximate to a bottom portion of the cap top end 102. The placement
of the magnetic field generating material 114 enables interaction
with an end section of a reinforcing bar 110 inserted into the
cylindrical cavity 108c. Although the cap top end 102 of protective
cap 100 is rectangular and the collar structure 108 is cylindrical,
as depicted in FIG. 1, as would be appreciated by one skilled in
the art, the cap top end 102 and the collar structure 108 can be
any combination of shapes and sizes configured to receive
reinforcing bars. For example, FIG. 2 depicts the protective cap
100 with a circular cap top end 102 and a cylindrical cap bottom
end 104.
[0032] FIG. 2 depicts another example illustrative view of the
protective cap 100. In particular, FIG. 2 depicts a transparent
view of the protective cap 100. FIG. 2 depicts the protective cap
100 as a single piece, or as provided in an example embodiment, two
cap halves 100a, 100b joined together to form a single piece. The
protective cap 100, as depicted in FIG. 2, includes the cap top end
102 including the crumple zone structure 106 (not depicted), the
cap bottom end 104 including the collar structure 108 with cap top
end 102 fixedly attached to the cap bottom end 104. FIG. 2 also
depicts the plurality of trusses 112 connected to the cap top end
102 and the cap bottom end 104, providing additional structural
integrity to the protective cap 100. FIG. 2 further depicts the
magnetic field generating material 114 embedded/included within a
cavity of the cap top end 102. As discussed herein, the magnetic
field generating material 114 can include any combination of a
magnetic material within a cavity or a plurality of particles
embedded material formed within the cap top end 102. Additionally,
FIG. 2 depicts the end section of reinforcing bar 110 inserted in
the cylindrical cavity 108c of the collar structure 108, positioned
for interaction with the magnetic field generating material
114.
[0033] FIG. 3 depicts an example illustrative cross-sectional view
of the protective cap 100. Additionally, the cross-sectional view
depicted in FIG. 3, represents one half of the two cap halves 100a,
100b combined to form the single protective cap 100. In particular,
FIG. 3 depicts an internal cross sectional view of the protective
cap 100 (or on cap half 100a or 100b) including the cap top end 102
with the crumple zone structure 106 and the cap bottom end 104
including the collar structure 108 with cap top end 102 fixedly
attached to the cap bottom end 104. The crumple zone structure 106,
as depicted in FIG. 3, is made up of a plurality of rectangular
crumble zones or cavities configured to absorb the impact of a
falling object. FIG. 3 also depicts the plurality of trusses 112
connected to the cap top end 102 and the cap bottom end 104,
providing additional structural integrity to the protective cap
100. FIG. 3 further depicts the magnetic field generating material
114 included within a cavity 114a of the cap top end 102. As would
be appreciated by one skilled in the art, the magnetic field
generating material 114 and the cavity 114a could be replaced with
magnetic particles injected/formed within this portion of the cap
top end 102. Additionally, FIG. 3 depicts the end section of
reinforcing bar 110 inserted in the cylindrical cavity 108c of the
collar structure 108 with the end of the inserted reinforcing bar
proximate to the magnetic field generating material 114. A magnetic
field 114f is generated by the magnetic field generating material
114 and interacts with the reinforcing bar 110. In accordance with
an example embodiment of the present invention, the protective cap
100 of FIG. 3 further includes a plurality of mechanically
interconnecting features 116 configured for join two cap half
pieces (e.g., 100a, 100b) together to form a single protective cap
100 structure.
[0034] FIGS. 4A-4C depict illustrative perspective views of two cap
halves 100a, 100b that are combinable to form a single protective
cap 100 structure. The two cap halves 100a, 100b, as depicted in
FIGS. 4A-4C, include the cap half top ends 102a, 102b including the
crumple zone structures 106a, 106b (including crumple
zones/cavities), the cap half bottom ends 104a, 104b including the
collar structures 108a, 108b with cap half top ends 102a, 102b
fixedly attached to the respective cap half bottom ends 104a, 104b.
FIGS. 4A-4C also depict the plurality of trusses 112 connected to
the cap half top ends 102a, 102b and the cap half bottom ends 104a,
104b, providing additional structural integrity to the overall
protective cap 100. In accordance with an example embodiment of the
present invention, the protective cap 100 of FIGS. 4A-4C further
includes a plurality of mechanically interconnecting features 116a,
116b configured for join two cap half pieces (e.g., 100a, 100b)
together to form a single protective cap 100 structure (e.g.,
inserting the tabs from one half into respective slots on the other
half).
[0035] FIG. 4A is an example illustration showing a partially
rotated side perspective view of the two cap halves 100a, 100b. In
particular, FIG. 4A depicts an alternate view all the elements that
make up the protective cap 100, as discussed herein. From the
partially rotated side view, an inside portion of the first cap
half 100a and reverse portion of the second cap half 100b is
depicted. The inside portion of the first cap half 100a shows the
internal of the crumple zone structure 106a including a plurality
of crumble zones/cavities. The two cap halves 100a, 100b are
configured to join together via the plurality of mechanically
interconnecting features 116a, 116b to form the protective cap 100.
FIG. 4A also depicts the internal cylindrical cavity portion 108c
of the first collar structure 108a. Additionally, FIG. 4A further
depicts the magnetic field generating material 114
embedded/included within a cavity of the first cap half top end
102a.
[0036] FIG. 4B is an example illustration showing a partially
rotated bottom view of the two cap halves 100a, 100b. In
particular, FIG. 4B depicts an alternate view all the elements that
make up the protective cap 100, as discussed herein. The partially
rotated bottom view of the two cap halves 100a, 100b shows the
internal cylindrical cavity portion 108c of the first collar
structure 108a and the 108b. Additionally, FIG. 4B depicts how the
two cap halves 100a, 100b are configured to join together via the
plurality of mechanically interconnecting features 116a, 116b to
form the protective cap 100.
[0037] FIG. 4C is an example illustration showing a side view of
the two cap halves 100a, 100b. In particular, FIG. 4C depicts an
alternate view all the elements that make up the protective cap
100, as discussed herein. Additionally, FIG. 4B depicts how the two
cap halves 100a, 100b are configured to join together via the
plurality of mechanically interconnecting features 116a, 116b to
form the protective cap 100.
[0038] In operation, the protective cap 100 is inserted onto
exposed ends of any sized reinforcing bars, or other construction
materials, to provide a protective barrier between objects and
exposed ends of reinforcing bars. In particular, a reinforcing bar
is inserted into the cylindrical cavity 108c of the collar
structure 108, as depicted in FIGS. 2 and 3. The end section of the
reinforcing bar 110 extends into the collar structure 108 and makes
contact with a bottom portion of the cap top end 102 of the
reinforcing cap 100. In accordance with an example embodiment of
the present invention, the end section of the reinforcing bar 110
is secured to the protective cap 100 by the magnetic pull provided
by the magnetic field generating material 114 located inside the
cap top end 102 of the protective cap 100. The magnetically secured
connection will prevent the protective cap 100 from dislodging
and/or falling off of the reinforcing bar, due to accidental
contact from individuals, vibration of the reinforcing bar, etc.
Additionally, the structural benefits of the combination of the
crumple zone structure 106 and the plurality of trusses will
protect an object falling on the protected end (e.g., by the
protective cap 100). Specifically, the protective cap 100 installed
on an end section of the reinforcing bar 110 will protect an object
weighing two-hundred and fifty pounds falling from a height up to
10 feet without failure of the protective cap 100. This level
protection provided by the cap meets the requirements of the OSHA
mandated drop test.
[0039] As utilized herein, the terms "comprises" and "comprising"
are intended to be construed as being inclusive, not exclusive. As
utilized herein, the terms "exemplary", "example", and
"illustrative", are intended to mean "serving as an example,
instance, or illustration" and should not be construed as
indicating, or not indicating, a preferred or advantageous
configuration relative to other configurations. As utilized herein,
the terms "about" and "approximately" are intended to cover
variations that may existing in the upper and lower limits of the
ranges of subjective or objective values, such as variations in
properties, parameters, sizes, and dimensions. In one non-limiting
example, the terms "about" and "approximately" mean at, or plus 10
percent or less, or minus 10 percent or less. In one non-limiting
example, the terms "about" and "approximately" mean sufficiently
close to be deemed by one of skill in the art in the relevant field
to be included. As utilized herein, the term "substantially" refers
to the complete or nearly complete extend or degree of an action,
characteristic, property, state, structure, item, or result, as
would be appreciated by one of skill in the art. For example, an
object that is "substantially" circular would mean that the object
is either completely a circle to mathematically determinable
limits, or nearly a circle as would be recognized or understood by
one of skill in the art. The exact allowable degree of deviation
from absolute completeness may in some instances depend on the
specific context. However, in general, the nearness of completion
will be so as to have the same overall result as if absolute and
total completion were achieved or obtained. The use of
"substantially" is equally applicable when utilized in a negative
connotation to refer to the complete or near complete lack of an
action, characteristic, property, state, structure, item, or
result, as would be appreciated by one of skill in the art.
[0040] Numerous modifications and alternative embodiments of the
present invention will be apparent to those skilled in the art in
view of the foregoing description. Accordingly, this description is
to be construed as illustrative only and is for the purpose of
teaching those skilled in the art the best mode for carrying out
the present invention. Details of the structure may vary
substantially without departing from the spirit of the present
invention, and exclusive use of all modifications that come within
the scope of the appended claims is reserved. Within this
specification embodiments have been described in a way which
enables a clear and concise specification to be written, but it is
intended and will be appreciated that embodiments may be variously
combined or separated without parting from the invention. It is
intended that the present invention be limited only to the extent
required by the appended claims and the applicable rules of
law.
[0041] It is also to be understood that the following claims are to
cover all generic and specific features of the invention described
herein, and all statements of the scope of the invention which, as
a matter of language, might be said to fall therebetween.
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