Abstract:
An edge impact protector ( 10 ) comprising an elongate resiliently deformable body comprising first and second flange portions ( 16 ) and ( 18 ) extending from a shock absorbing corner portion ( 14 ), said first and second shock absorbing flange portions  16  and ( 18 ) carrying separate respective first and second relatively rigid elongate mounting plates ( 22 ) and ( 24 ), the first and second mounting plates ( 22 ) and ( 24 ) enabling the edge impact protector ( 10 ) to be mounted over an edge.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to the field of safety edging, and in particular to edge impact protectors or bumpers configured to cover hard edges and corners so as to prevent injuries arising from impacting such edges. 
       BACKGROUND OF THE INVENTION 
       [0002]    Many Injuries arise from impact against hard corners or edges in various environments. Installations such as stairs, kerbs and various types of railings all have hard edges which constitute a potential safety hazard, in that they present an impact zone which is potentially penetrative and unyielding. 
         [0003]    An average of 19 children are apparently admitted to hospital per day in NSW with a playground related injury, with the highest rate of injury occurring in children between the ages of one and five. Most playground injuries relate from a fall from playground equipment. A significant proportion of arm and head related injuries arise from collision of a child&#39;s arm or head with a hard edge. 
         [0004]    The inclusion of cushioning materials which attenuate the impacts associated with a fall from heights have reduced injuries. However there is still a significant injury risk associated with many playgrounds in both Australia and the rest of the world. 
         [0005]    It is known in related art to use releasably attachable bumpers that may be attached to the edges of tables, chairs and the like. U.S. Pat. No. 5,639,072 to McCall teaches a bumper that is a cushion which is essentially cylindrical, with a section cut out along the longitudinal axis to form a slot along the length of the bumper. The bumper is attached to the edge of the furniture using a plurality of releasable Velcro-type fasteners. 
         [0006]    Other Systems using releasable attachment means for the bumper cushion to furniture are best suited to indoor applications in relatively controlled environments. For example, U.S. Pat. No. 5,527,097 to Martin teaches an edge member for a chair which has a chamber with a pair of flanges connected by a beam perpendicular to the flanges, the edge member secured to the chair using staples to attach the flanges to either side of the chair frame. 
         [0007]    U.S. Pat. No. 5,283,096 to Greenberg teaches a flexible protective strip that locks into a metal or plastic longitudinally extending channel section which is affixed to a surface between edges. However, it is relatively complex in construction and significantly increases the profile of the protected edge. 
         [0008]    Accordingly the present inventor has identified shortcomings in the systems and methods of the prior art and has sought ameliorate at least some of the deficiencies and problems associated with these systems and methods. These and other advantages of the present invention will become apparent from reading the following description. 
         [0009]    Any discussion of documents, publications, acts, devices, substances, articles, materials or the like which is included in the present specification has been done so for the sole purpose so as to provide a contextual basis for the present invention. Any such discussions are not to be understood as admission of subject matter which forms the prior art base, or any part of the common general knowledge of the relevant technical field in relation to the technical field of the present invention to which it extended at the priority date or dates of the present invention. 
       SUMMARY OF THE INVENTION 
       [0010]    In one aspect the present invention provides an edge impact protector comprising an elongate resiliently deformable body comprising first and second shock absorbing flange portions extending from a shock absorbing corner portion, said first and second flange portions carrying separate respective first and second relatively rigid elongate mounting plates, the first and second mounting plates enabling the edge impact protector to be mounted over an edge. 
         [0011]    Advantageously, the first and second mounting plates define first and second relatively rigid mounting zones and the shock absorbing corner portion defines an intermediate flexible zone for allowing an included angle defined between the first and second flange portions to be varied depending on the angle between adjacent surfaces between which the edge is defined. The included angle of the edge impact protector may be varied by plus or minus 30 degrees. 
         [0012]    The first and second mounting plates may each be formed with at least one mounting aperture for receiving mechanical fasteners for mounting the impact protector over the edge. The flange portions may also be formed with apertures which align with corresponding apertures formed in the mounting plates, the portions being of a depth sufficient to allow heads of said mechanical fasteners to be recessed. 
         [0013]    Preferably the edge impact protector has a profile arranged to vary in substantial conformity with the profile of an edge being covered. 
         [0014]    For example, the edge impact protector may have a profile which is substantially L-shaped, substantially U-shaped, or substantially V-shaped. 
         [0015]    The first and second inner faces of the first and second flange portions may be formed with recesses for receiving the respective first and second mounting plates, with the mounting plates being bonded in position within the recesses. 
         [0016]    Alternatively, the first and second mounting plates may be encapsulated at a depth of between 1 mm and 3 mm within the first and second flange portions respectively. 
         [0017]    Advantageously, the shock absorbing corner portion has an elongate cavity defined therein, the cavity bounded by an outer arcuate web and an inner corner defining web which are arranged to facilitate flexibility of the intermediate flexible zone. 
         [0018]    Each end of the cavity may be sealed to provide a closed air cell providing a pneumatic cushion. The cavity may be filled with a cushioning material such as a closed cell foam material. 
         [0019]    The shock absorbing portion of the edge impact protector may comprise a protruding bumper which extends beyond the planes of the outer surfaces of the first and second flange portions. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]      FIG. 1  shows a top perspective of the first embodiment of an edge impact protector; 
           [0021]      FIG. 2  shows an end-on view of the edge impact protector of  FIG. 1 ; 
           [0022]      FIG. 3  shows a cross-sectional view of the edge impact protector of  FIGS. 1 and 2  mounted in position on a hard edge; 
           [0023]      FIG. 4  shows a top perspective view of a second embodiment of an edge impact protector of the invention; 
           [0024]      FIG. 5  shows an end-on view of the edge impact protector of  FIG. 4 ; and 
           [0025]      FIG. 6  shows an end on view of an impact protector according to a second embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0026]    Referring first to  FIGS. 1 and 2 , a first embodiment of an edge impact protector or bumper  10  of the invention comprises a resiliently deformable body  12  formed from VIBRATHANE® 6012 manufactured by Crompton Uniroyal Chemical. This is a mid-terminated polyester based prepolymer which is extended with a curative such as Moca® by Eracure to yield a urethane having hardness varying from 87A to 53D, typically around 60D. Alternatively, various resilient synthetic or natural rubber materials may be used, which have the desired cushioning effect. 
         [0027]    The deformable body  12  has a shock absorbing corner portion  14  from which first and second shock absorbing flange portions  16  and  18  extend. The corner portion is formed with a cavity  20  having a part circular profile and defining an outer arcuate web  40  and an inner corner defining web  42 , in an alternative form of the invention, the cavity may be filled with polyurethane foam. 
         [0028]    Recesses  16 A and  18 A are defined in the inner surfaces of the respective flange portions  16  and  18 , and receive elongated steel plates  22  and  24  in a snug fit. 
         [0029]    During production, the steel plates are typically held in position with magnets within the mould cavity. The inner surfaces of the steel plates may be sand blasted to facilitate adhesion with the polyurethane body. The steel plates  22  and  24  are then integrally moulded with the polyurethane body. The plates may be formed other metals or metal alloys such as aluminium. 
         [0030]    When carried by the flanges  16  and  18  the steel plates  22  and  24  form relatively rigid mounting zones in those flanges. The intermediate corner portion provides a flexible zone between these rigid mounting zones. As discussed below, the deformability of the VIBRATHANE® and the independence of the mounting zones allow the flanges to be moved relative to one another to very the included angle of the protector. This in turn allows the protector to be fitted to edges having adjacent surfaces which are of an angle of greater or less than 90 degrees or which are irregular along their length. 
         [0031]    In an alternative form of the invention, as shown in  FIG. 6 , the edge impact protector is produced with steel plates  22  and  24  encapsulated entirely within the flange portions  16  and  18  of the body. This form of the invention may be produced by offsetting the steel plates  22  and  24  from the mould surface prior to introducing the polyurethane. The polyurethane then fills the gaps between the steel plates  22  and  24  and the mould edge and sets such that the steel plates  22  and  24  are encapsulated within the body at a depth of 2 mm from the edges of the flanges which mount on the edge. 
         [0032]    In a further alternative form of the invention, the body may be extruded and the plates subsequently bonded in position using a suitable adhesive. In the particular embodiment, the stainless plates are 20 mm wide and 1.2 mm thick. In the manufacturing process, lengths of typically 1 m or more are provided, which are then cut to size. Typically, in a playground environment the edge strip assemblies are cut to lengths of around 900 mm. The mounting plate may be co-extensive with the flanges, or may be provided at shortly spaced intervals. By providing gaps between successive plates, the flanges may be more easily cut to a desired length. In addition, the gaps provide a zone of flexure for enabling protectors to be fitted to edges which are not rectilinear. 
         [0033]    Each plate has a chamfered edge  25  which contacts a complemental angled face  25 A of the body to assist in holding the distal ends of the body in place against an edge face. 
         [0034]    As can be seen from  FIGS. 1 and 3 , both the flanges  16  and  18  and the stainless steel plates  22  and  24  have respective apertures  26  and  28  formed at regular intervals for receiving mechanical fasteners such as screws  30 , rails or rivets. The flanges  16  and  18  are formed with recesses in the polyurethane aligning with the apertures  26  and  28  in the plates  22  and  24 . The depth of the recesses is greater than the height of the screw head so that the head is not exposed to provide an injury hazard. In  FIG. 3 , the edge impact protector is shown mounted firmly in position over the corner of a wooden sleeper  32  having top and side faces  34  and  36  respectively. 
         [0035]    Referring now to  FIGS. 4 and 5 , a second embodiment of an edge impact protector  38  is shown which is arranged to be fitted over concrete steps. The edge impact protector is similar to that of  FIGS. 1 to 3 , save that it is formed with longer flanges  16  and  18 . If desired the length of the Mounting plates  22  and  24  may be extended to account for the longer flanges  16  and  18 . Alternatively, additional mounting plates may be provided along the length of each flange  16  and  18  to provide for more flexibility in each of the flanges  16  and  18 . It will be appreciated that in certain embodiments the relative lengths of the flanges  16  and  18  may vary. 
         [0036]    In both of the embodiments described, the edge impact protector has an included angle of 90°. It will be appreciated that numerous other included angles may be provided, depending upon the configuration of the edge being protected. Further, an advantage of the edge impact protector is that as the assembly is provided with independent mounting plates  22  and  24  the protector  10  is deformable at the corner portion. The deformability of the protector  10  will depend on the elasticity of the material being used, as well as on the particular profile. The cavity  20  facilitates deformation as the outer arcuate web  40  and inner corner defining web  42  of the corner portion are able to deform more readily. 
         [0037]    Variation of plus or minus 30 degrees from the original included angle may be achieved with a protector of the type illustrated in  FIGS. 1 to 6 . For example, in the case of an L-shaped protector (having an original included angle of 90°), the protector may be configured to fit snugly over edges having a varying range of included angles between 10 degrees and 120 degrees. At the same time, the relatively rigid mounting plates allow the edge strip assemblies to be mounted firmly in position in harsh outdoor environments where they need to be mounted sufficiently firmly to withstand heavy pedestrian traffic, vandals and varying weather conditions. Alternatively, the protectors may be mounted in heavy traffic environments, for example on the steps of buses. 
         [0038]    In an alternative form of the invention, the edge impact protector may be bonded to the surfaces of an edge using a suitable adhesive. The edge is prepared by applying a suitable sealer such as Bostik® N49 sealer to the surfaces of the edge to be covered. Thereafter, an adhesive such as Bostik Sikaflex® is applied to the edge and inner surfaces of the sealed plates before bonding the edge impact protector in position. 
         [0039]    The particular profile of the edge impact protector not only provides an impact absorbing function, but also a grippable non-slip surface. In addition, depending on the colour of the edge strip protector, it may act as a visual aid. It can also act as a tactile edge indicator allowing for unsighted notification of an edge. 
         [0040]    It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention. 
         [0041]    It will also be understood that the term “comprises” (or its grammatical variants) as used in this specification is equivalent to the term “includes” and should not be taken as excluding the presence of other elements or features.