Patent Publication Number: US-10307652-B2

Title: Climbing hold assembly having load dissipative effect

Description:
PRIORITY CLAIM 
     This application claims priority to U.S. Provisional Patent Application No. 61/816,246 filed Apr. 26, 2013, which is hereby incorporated herein by reference. 
    
    
     BACKGROUND 
     Polycarbonate or thermoplastic panels used in climbing walls and the likes may experience cracking. A climbing panel, while extremely strong and durable, may be subject to radial stress cracks specifically located around the edge of a hole pre-drilled in the panel, which is used to affix a climbing hold to the panel of the climbing structure. 
     The current method of attaching climbing holds to polycarbonate or thermoplastic sheet that form the panels of a climbing surface is to use a combination of a bolt, flat and locking washers, and either a nut, an embedded nut (‘T’ Nut) or a threaded insert. When attaching the climbing hold the assembler needs to exert sufficient torque on the bolt creating compressive forces between the climbing hold and the panel in order to prevent the climbing hold from spinning. The majority of compressive forces exerted on the panel, using the current method, are located immediately around the edges of the pre-drilled hole in the panel and this dramatically increases the possibility of the panel cracking or fracturing in a Tangential/Radial direction away from the hole. Coupled with the live load exerted on the climbing hold by a climber, these radial cracks or fractures have the potential to extend and creep into a full crack, not dissimilar to that of a cracked windshield. 
     Such radial cracks or fractures may not be immediately detectable, particularly if the climbing hold or the hardware used to affix a climbing hold to the panel obscures them. They are, nonetheless, serious in that the integrity of the panel is compromised, potentially worsens over time with live stress loads, and cannot be repaired. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Example embodiments of the present disclosure will be described below with reference to the included drawings such that like reference numerals refer to like elements and in which: 
         FIGS. 1 a  and 1 b    illustrate is an example of a climbing hold or handhold, consistent with certain implementations. 
         FIGS. 2 a  and 2 b    illustrate a top view and a cross-sectional view of an exemplary load dissipation nut with cavity, consistent with certain embodiments. 
         FIGS. 3 a  and 3 b    illustrate top and isometric views of a neoprene washer, consistent with certain embodiments. 
         FIG. 4  is a side view of a climbing hold assembly, consistent with certain embodiments. 
         FIG. 5  is a perspective view of a climbing hold assembly, consistent with certain embodiments. 
         FIGS. 6 a -6 c    illustrates a disassembled load dissipation assembly, in which a cavity formed in an underside of a climbing hold, a cavity of an underside of a load dissipation element, and a top side of the load dissipation element can be seen, consistent with certain embodiments. 
         FIGS. 7 a , 7 b , and 7 c    illustrate top, cross-sectional, and isometric views of a load dissipation plate with cavity, consistent with certain embodiments. 
         FIG. 8  illustrates a top view of a climbing hold affixed to a panel, consistent with certain embodiments. 
         FIG. 9  illustrates a cross-sectional view of a load dissipation assembly that employs a load dissipation nut, consistent with certain embodiments. 
         FIG. 10  illustrates a cross-sectional view of a load dissipation assembly that employs a load dissipation plate, consistent with certain embodiments. 
         FIGS. 11 a , 11 b , and 11 c    illustrate top, cross-sectional, and isometric views of an illustrative load dissipation nut, consistent with certain embodiments. 
         FIGS. 12, 13 and 14  illustrate cross-sectional views of climb hold assemblies that employ a load dissipation nut, consistent with certain further embodiments. 
         FIGS. 15, 16 and 17  illustrate cross-sectional views of climb hold assemblies that employ a load dissipation plate, consistent with certain further embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     For simplicity and clarity of illustration, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. Numerous details are set forth to provide an understanding of the embodiments described herein. The embodiments may be practiced without these details. In other instances, well-known methods, procedures, and components have not been described in detail to avoid obscuring the embodiments described. The description is not to be considered as limited to the scope of the embodiments described herein. 
     The terms “a” or “an”, as used herein, are defined as one or more than one. The term “plurality”, as used herein, is defined as two or more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. Reference throughout this document to “one embodiment”, “certain embodiments”, “an embodiment”, “an example”, “an implementation”, “an example” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment, example or implementation is included in at least one embodiment, example or implementation of the present invention. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment, example or implementation. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments, examples or implementations without limitation. 
     The term “or” as used herein is to be interpreted as an inclusive or meaning any one or any combination. Therefore, “A, B or C” means “any of the following: A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive. 
     In accordance with the various embodiments described herein there is provided an assembly that serves to dissipate the compressive forces experienced by panels, such as climbing panels, affixed to a climbing apparatus, such as a climbing scaffold that provides structure support and shape for a climbing wall or climbing feature. A problem in the art experienced with panels made of polycarbonate or thermoplastic sheet is that, while extremely strong and durable, compressive forces experienced in the panel material can produce fracturing and cracking directly around the edge of a pre drilled hole in the panel, particularly where hardware is placed through the hole to affix a climbing hold to the panel. The use of load dissipation elements with a cavity, such as a load dissipation nut, a load dissipation plate, and a cavity backed climbing hold, in a climbing hold assembly serves to dissipate these compressive forces away from the hole location in the panel and thus greatly reduces or eliminates fractures and cracking in the panel. The climbing hold assembly dissipates compressive stress from the hole location and dissipates the load over a greater surface area of the panel. In this way, compressive forces are distanced away from the drilled hole location. In certain embodiments, the compressive forces are distanced away from the drilled hole edges by a minimum of 1× the diameter of the drilled hole, thereby being in compliance with safety recommendation of polycarbonate sheet manufacturers. It is noted that the distance by which compressive forces are displaced away from the drilled hole edges may change with improvements in material science, as may the safety recommendations of panel manufacturers, without departing from the scope of the embodiments presented herein. 
     A climbing hold assembly in accordance with the present teachings may include a climbing hold and a load dissipation element with a cavity, a bolt, a neoprene washer, a flat steel washer and nut, or the like. In a method of assembly, the climbing hold is affixed to a polycarbonate or thermoplastic sheet or panel by placing a bolt through the climbing hold, the sheet or panel of polycarbonate or thermoplastic material, an optional neoprene washer, the load dissipation element with cavity, the bolt being tightened into place with the necessary torque. A cavity formed in the underside of the handhold that rests against the polycarbonate panel is in communication with a corresponding cavity on the underside of the load dissipation element that makes contact with the polycarbonate panel. The dimensions of the cavity of the climbing hold approximate that of the dimensions of the cavity of the load dissipation element, with the dimensions of the cavity of the load dissipation element being at least three times that of the diameter of the hole through the polycarbonate material. Thus, as an example, in an application in which the hole through the polycarbonate material is ¼ inch, the cavity in the load dissipation element will be at least ¾ inch and will approximate the size and shape, or volume, of the cavity of the climbing hold. 
     Thus, marrying the dimensions of the cavities of the climbing hold and the load dissipation element is useful for reducing or even eliminating the compressive forces experienced by the climbing hold assembly, directly at the edges of the pre drilled hole so as to prevent or greatly reduce the occurrence of radial cracking in the polycarbonate or thermoplastic panel. 
     An example handhold or climbing hold is illustrated in  FIGS. 1 a  and 1 b   , in which both top and cross-sectional views are shown. In the top view of  FIG. 1 a   , climbing hold  10  is shown with a cavity in the underside (on the bottom) of climbing hold  10 , as indicated by the dashed lines. Also illustrated is hole  14  in the climbing hold through which a fastening element may pass to affix or fasten the climbing hold to a panel or sheet of material. Hole  14  in this particular embodiment is shown centered in the middle of cavity  12 , though in other embodiments hole  14  need not be centered in cavity  12  so long as it located within the cavity  12  to allow a fastening element to pass through the cavity  12  in the underside of climbing hold  10 . In the cross-sectional view of climbing hold  10  in  FIG. 1 b   , it can be seen that the body of the climbing hold is formed of material  16 . Cavity  12  is formed in the underside of the climbing hold and the outline of the cavity  12  in the bottom surface  17  of climbing hold  10  has a shape, in this instance a circular shape as can be seen in the dashed lines in  FIG. 1 a   . Cavity  12  may be considered a region of the climbing hold formed in the underside of the climbing hold as shown, with the region being the absence of material or cavity. Optionally, climbing hold  10  may have a backing  18  on the bottom of surface  17  of a softer material than the material  16  of the climbing hold body to cushion the mating of climbing hold  18  to a panel in a climbing hold assembly and to, importantly, inhibit rotation of the climbing hold when torque forces are applied to the fastening element during assembly of the climbing hold assembly. Alternately, soft backing  18  may be a softer portion of the bottom surface of climbing hold  18  and not a backing separate from the body of the climbing hold  10 . 
     Other examples of climbing handholds can be seen in  FIGS. 4, 6, 9 and 10 . The size, shape, dimensions and materials of climbing handholds can and do vary widely. For example, while the cavity  12  is shown as being circular in shape in the bottom surface  17  of the climbing hold, the shape of the cavity at the bottom surface  17  may be any shape in the bottom surface of the climbing hold through which a fastening element may pass through hole  14  to fasten the climbing hold to a panel. The cavity of the handhold can be clearly seen in the views in the drawings, and as will be also illustrated in the climbing hold assemblies in  FIGS. 9 and 10  the dimensions of the cavity of the climbing hold will be approximated by the dimensions of the cavity of the load dissipative element mated or aligned with it via the panel in the assembly. 
     As previously mentioned, the load dissipation element may be a load dissipation nut or a load dissipation plate, and both types in certain embodiments will have a cavity with a dimension that approximates that of the cavity of the handhold to which it is mated or aligned via the panel in a climbing hold assembly. In  FIGS. 2 a  and 2 b   , top and cross-sectional views of a load dissipation nut  20  are shown with a cavity  22 . Cavity  22  may be considered a region formed in the underside of the load dissipation nut as shown, with the region being the absence of material or cavity. The dimensions, including size and shape, or volume, of the load dissipation nut cavity  20  will match or approximate that of the cavity of the climbing hold to which is it coupled, as shown in  FIG. 9 , for example; in this case, the shape of cavity  22  is circular although other sizes and shapes could be used. For instance, the circular cavity of the load dissipation nut may have a diameter of 1.5 and the climbing hold cavity may also be circular with a diameter of 1.5 or closely to 1.5.  FIG. 2 a    illustrates the top view of the load dissipation nut; the bottom surface  26  of the load dissipation nut will be in contact with either the polycarbonate or thermoplastic material of the panel or optionally a neoprene washer  30  with hole  32  shown in the top and isometric views of  FIGS. 3 a  and 3 b   , respectively. In this example, the load dissipation nut is threaded to accommodate a bolt or other fastening element that passes through hole  24  and is used to secure the load dissipation nut to the polycarbonate panel and climbing hold. While the washer of  FIGS. 3 a  and 3 b    is referred to as a neoprene washer, this is but one example of a suitable material. For example, other flexible types of material, such as urethane may be used as well. 
     A further illustration of a load dissipation nut is found in  FIGS. 11 a , 11 b , and 11 c   , in which top, cross-sectional, and isometric cut-away views of an example threaded load dissipation nut are shown. In the top view of  FIG. 11 a   , load dissipation nut  110  is shown with a threaded hole  114  which can accommodate a fastening element that passes therethrough. A cavity  112  is formed in the underside of load dissipation nut  110 . In the cross-sectional view of  FIG. 11 b   , it can be seen that the nut is formed of a material  116  that surrounds the cavity  112  formed in the underside of nut  110 . In the cut-away isometric new of nut  110  in  FIG. 11 c   , the threaded hole  114  and the shape of cavity  112  is clearly illustrated. 
     As previously mentioned, in certain embodiments the dimensions of the cavity of the load dissipation element may be at least approximately three times that of the dimension of the hole through the polycarbonate panel material. So, in this example, the diameter of the hole through the polycarbonate sheet may be 0.438 while the diameter of the cavity of the load dissipation nut is at least three times that, or 1.5. Similarly, in certain embodiments, the dimensions of the cavity of the climbing hold may be at least approximately three times that of the dimension of the hole through the panel material. It is noted that the dimensions of either the climbing hold or the load dissipation element in the assembly with respect to the dimensions of the through hole in the panel may change with improvements in material science, without departing from the scope of the embodiments presented herein. 
     For climbing walls and apparatus used in an aquatic environment, metals that are non-ferrous, such as stainless steel, brass, bronze, aluminum, etc. may be used to produce the load dissipation element, alternatively high strength plastic materials such as Ultem and pultruded fiberglass may be used. 
       FIGS. 4-5  illustrate various views of a load dissipation assembly in use.  FIG. 4  is a side view of a climbing hold assembly  40 , with the climbing hold  42  on the bottom of panel  44  and the load dissipation element  46  on top of the panel  42 . The entire assembly is coupled together with a fastening element, such as a bolt or screw  48 , or other fastening element, shown at the top of the assembly. Also shown in the optional neoprene washer  49 .  FIG. 5  offers a perspective view of the climbing hold assembly  40 , in which, again, the load dissipation element is shown on top of the polycarbonate panel. The panel  44  is of a clear or see-through material such that the climbing hold  42  fastened to the bottom surface of panel  44  is seen. 
       FIGS. 6 a -6 c    illustrate a disassembled load dissipation assembly, minus the fastening element bolt or screw, in which a cavity formed in an underside of a climbing hold in  FIG. 6 a   , a cavity of an underside of a load dissipation element in  FIG. 6 b   , and a top side of the load dissipation element can be seen in  FIG. 6 c   . In the bottom view of climbing hold  50 , the region formed in the underside of the climbing hold is a cavity  52 , circular in shape. Hole  54  of climbing hold  50  passes through the cavity and body portion of the hold as shown. In the bottom perspective view of load dissipation nut  60  of  FIG. 6 b   , the bottom surface  66  is shown and it can be seen that the shape of the cavity  62  formed in the bottom surface is circular. Again, the shape of the cavity  62  at the bottom surface  66  may be any shape in the bottom surface of the load dissipation nut through which a fastening element may pass through hole  64  to fasten the load dissipation nut to a surface of a panel. In the top perspective view of  FIG. 6 c   , load dissipation nut  60  with hole  64  is shown. 
     As previously discussed, the load dissipation element may also be a load dissipation plate (or washer) that would, again, have a cavity region of the load dissipation element configured to mate with a corresponding cavity region of a climbing hold to which it is coupled in a load dissipation assembly. To do this, the size and shape dimensions, or volume, of the cavity of the load dissipation plate will approximate those of the cavity of the climbing hold. The load dissipation plate may be pressed steel or stainless steel with cavity or it may be a load dissipation plate with cavity that can be made of numerous other materials employed without departing from the scope described herein. 
     An example of a pressed load dissipative plate  70  with hole  72 , cavity  78  and bottom surface  76  is illustrated in  FIGS. 7 a , 7 b , and 7 c   , in which top, cross-sectional, and isometric views are shown. Unlike the load dissipation nut of  FIGS. 2 and 3 , in this example the load dissipative plate is not threaded. 
     In  FIG. 8  a top view of a polycarbonate panel  80  is shown with a hand hold or climbing hold  82  affixed to it. As discussed above, the hold is attached to the polycarbonate panel by a screw, bolt or other fastening device or element  84  that passes through a hole  86  of the climbing hold, a hole in the panel and mates with a load dissipation element affixed to the bottom surface of the panel, to create a load dissipation assembly. 
     Two such assemblies are illustrated in  FIGS. 9 and 10 . In the cross-sectional view  FIG. 9 , the load dissipation assembly includes the climbing hold  90 , a fastening element  91  that passes through the hold, a hole in the panel and mates with a load dissipation nut  97  having a bottom region  98  affixed to the bottom surface  95  of the panel  96 . The cavity region  94  of the hold  90  and the cavity region  99  of the load dissipation nut  97  are approximately the same size and shape, or volume, as shown. The load dissipation nut  97  resembles that illustrated in  FIGS. 2 and 3  and has a generally conical shape as shown. As will be illustrated in later drawings  FIGS. 12, 13 and 14 , the region formed in the underside of the climbing hold as well as the region formed in the underside of the load dissipation nut in the climbing hold assembly may be either a cavity region or a region of softer material characterized as having a measure of hardness, such as a Durometer rating, that is less than that of the material that surrounds and is contiguous the region of softer material. Examples of softer material for the regions formed in the underside of the climbing hold and/or the underside of the load dissipation element include natural sponge, rubber, polystyrene rubber, silicon sealant, silicon, paste, beads, etc. 
       FIG. 10  shows a cross-sectional view of a load dissipation assembly that includes a load dissipation plate  107  coupled to a climbing hold  100  through a bolt, screw or other fastening device  101 , passed through a hole  102  in the hold, a hole in the panel and the load dissipation plate  107  and affixed to the bottom surface  106  of the panel using an optional flat washer  108 , and locking nut  103  as shown. Again, the cavity of the hold and the cavity of the load dissipation plate are approximately the same size and shape, or volume, as shown. The load dissipation plate resembles that illustrated in  FIGS. 7 a -7 c   . As will be illustrated in later drawings  FIGS. 15, 16 and 17 , the region formed in the underside of the climbing hold as well as the region formed in the underside of the load dissipation plate in the climbing hold assembly may be either a cavity region or a region of softer material characterized as having a measure of hardness, such as a Durometer rating, that is less than that of the material that surrounds and is contiguous the region of softer material. 
     Referring now to  FIGS. 12, 13, and 14 , it can be seen that in a climbing hold load dissipation assembly comprised of a climbing hold  90 , a panel  96  and a load dissipation nut  97 , that the regions formed in the underside of the climbing hold and in the underside of the load dissipation nut may be either a cavity region and/or a region of softer material. In  FIG. 12 , climbing hold  90  has a region  120  of softer material having a measure of hardness that is less than a measure of hardness of material  122  of the body of climbing hold  90  that surrounds and is contiguous the region  120 , as shown. In the particular example embodiment of  FIG. 12 , the region formed in the underside of load dissipation nut  97  is a cavity region  99  as shown in  FIG. 9 . In  FIG. 13 , the cavity region  94  formed in the underside of climbing hold  90  is as shown in  FIG. 9 . The region  130  formed in the underside of load dissipation nut  97 , however, is of a material characterized by a measure of hardness that is less than a measure of hardness of material  132  of load dissipation nut that surrounds and is contiguous region  130 , as shown. In  FIG. 14 , both underside regions  140  and  142  are regions having material that is softer than the material that surrounds and is contiguous them. So, for example, region  140  formed in the underside of hold  90  is surrounded by material  145  of hold  90  that is harder than the material in region  140 . Similarly, the region  142  formed in the underside of load dissipation nut  97  is surrounded by material  147  that is harder than the material in region  142 . The measure of hardness of the material in regions  140  and  142  may be approximately the same or they may differ from each other in their Durometer rating. In each of the climbing hold example assemblies shown in  FIGS. 12-14 , the shape of the region in the bottom surface of the climbing hold and the shape of the region in the bottom surface of the load dissipation are approximately the same so that compressive forces introduced by applying torqueing forces to assembly the climbing hold assembly to the panel  96  are dissipated away from the panel through hole as has been described. 
     Referring now to  FIGS. 15, 16, and 17 , it can be seen that in a climbing hold load dissipation assembly comprised of a climbing hold  100 , a panel  106  and a load dissipation nut  107 , that the regions formed in the underside of the climbing hold and in the underside of the load dissipation nut may be either a cavity region and/or a region of softer material. In  FIG. 15 , climbing hold  100  has a region  150  of softer material having a measure of hardness that is less than a measure of hardness of material  152  of the body of climbing hold  100  that surrounds and is contiguous the region  150 , as shown. In the particular example embodiment of  FIG. 12 , the region formed in the underside of load dissipation nut  107  is a cavity region  109  as shown in  FIG. 10 . In  FIG. 16 , the cavity region  104  formed in the underside of climbing hold  100  is as shown in  FIG. 10 . The region  160  formed in the underside of load dissipation nut  107 , however, is of a material characterized by a measure of hardness that is less than a measure of hardness of material  162  of load dissipation nut that surrounds and is contiguous region  160 , as shown. In  FIG. 17 , both underside regions  170  and  172  are regions having material that is softer than the material that surrounds and is contiguous them. So, for example, region  170  formed in the underside of hold  100  is surrounded by material  172  of hold  100  that is harder than the material in region  170 . Similarly, the region  174  formed in the underside of load dissipation nut  107  is surrounded by material  176  that is harder than the material in region  174 . The measure of hardness of the material in regions  170  and  174  may be approximately the same or they may differ from each other in their Durometer rating. In each of the climbing hold example assemblies shown in  FIGS. 15-17 , the shape of the region in the bottom surface of the climbing hold and the shape of the region in the bottom surface of the load dissipation are approximately the same so that compressive forces introduced by applying torqueing forces to assembly the climbing hold assembly to the panel  106  are dissipated away from the panel through hole as has been described. 
     The implementations of the present disclosure described above are intended to be examples only. For example, while polycarbonate or thermoplastic panels are discussed, the panels may additionally be made of glass or other suitable material. Those of skill in the art can effect alterations, modifications and variations to the particular example embodiments herein without departing from the intended scope of the present disclosure. Moreover, selected features from one or more of the above-described example embodiments can be combined to create alternative example embodiments not explicitly described herein. 
     The present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.