GB2499638A

GB2499638A - Multi-faced grooved structural element

Info

Publication number: GB2499638A
Application number: GB201203185A
Authority: GB
Inventors: Robin Mckenzie
Original assignee: RTD ENGINEERING Ltd
Current assignee: RTD ENGINEERING Ltd
Priority date: 2012-02-24
Filing date: 2012-02-24
Publication date: 2013-08-28
Anticipated expiration: 2032-02-24
Also published as: GB2499638B; GB201203185D0

Abstract

A multi-faced grooved structural element 2 has at least one longitudinal groove formed on a first face 8, 8 of the element. A second face 6 has a substantially smooth surface which may be a concave curve comprising a section of a circular curve.

Description

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Title: Improvements in or relating to Grooved Structural Elements Field of the Invention

The present invention relates to a grooved structural element, to multi-component structures comprising the grooved structural element; and especially to vehicles comprising such multi-component structures. The invention also relates to a method of making the aforementioned grooved structural element and to a method of making a multi-component structure.

Background of the Invention

It is well known in several industries to make use of grooved structural elements or profiles. These are usually made of metal such as steel or aluminium. The elements are typically provided as sections which can be cut to a desired length. Other elements or components can be slidably inserted into the grooves of the structural element by relative longitudinal movement of the structural element and the component to be inserted. In this way, multi-component structures can be built up to produce, for example, building frames for partitions, display frames for promotional material and the like.

A typical grooved structural element is described in EP 1,378,672, which also discloses a screw-threaded connecting means for connecting grooved structural elements one to another.

The structural element comprises a substantially rectilinear extruded profile of generally square section. Within each of the four faces of the element is provided a cup-shaped longitudinal groove, with flange portions extending partially across the opening of the grooves in the faces of the element. Accordingly, a suitably shaped and dimensioned component can be introduced into the groove at an end of the element by relative longitudinal movement of the element and the component to be inserted therein. The flange portions partially extending across the opening or mouth

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of the groove prevents the inserted component from being pulled out of the element by a transverse movement.

In EP 1,378,672 the grooves in the structural element are shaped and dimensioned to accommodate the screw head of a screw threaded connecting means.

The present invention relates to a novel design of grooved structural element which has a number of advantages relative to conventional structural elements.

Summary of the Invention

In a first aspect, the invention provides a multi-faced grooved structural element having at least one longitudinal groove formed on a first face of the element, and a second face which has a substantially smooth surface.

For present purposes, a "substantially smooth surface" is understood to mean that the majority of the surface of the relevant face of the element has no significant projections high enough and long enough, or recesses deep enough and long enough, as the case may be, to allow the finger tips of a normal adult to acquire a purchase on the face. Typically the smooth surface will extend over at least 75% of the area of the second face of the element, preferably over at least 80%, more preferably over at least 85%, and most preferably over at least 90% of the area of the second surface. In some embodiments the entire surface area of the second face of the element will be smooth.

It will be understood that very small projections or recesses may be present in the surface (e.g. of a height or depth of less than 0.2cm) but these will not interfere with the working of the invention because they will be too shallow to allow the finger tips of a normal adult to obtain a purchase. Alternatively, higher projections may be present, but if these are less than, say, 0.1cm wide, and widely spaced (e.g. by more than 2cm) then they will not afford a purchase. Deeper recesses may similarly not afford a purchase if their openings are too small to permit a finger tip to be inserted therein.

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In preferred embodiments, the smooth surface will be essentially level and not include any variation in height greater than +/- 0.1cm. Conveniently the element will have a smooth surface finish of 3 urn RMS or less, preferably 1 am RMS or less.

In some embodiments, the second face of the element will be substantially linear. In other embodiments the second face of the element may comprise a substantially smoothly contoured convex curve (when viewed in transverse cross section). However, in preferred embodiments the second face of the element will comprise or consist of a substantially smoothly contoured concave curve (when viewed in transverse cross section). This provides the advantages of the invention, whilst minimising the amount of material in the finished element and thereby minimising the weight thereof. This is especially desirable when the element is to be used to form structures in vehicles.

The grooved structural element may be formed of any suitable material, but a metal or metal alloy is preferred, such as steel or aluminium. Desirably the element is formed from, or comprises, extruded aluminium, especially anodised aluminium.

The longitudinal groove formed in the first face of the element is preferably provided with flange portions extending partially across the mouth of the groove from each edge, with a gap between, such that a component can be introduced into the groove at an end thereof by relative longitudinal movement of the element and the component to be inserted therein, in which typically at least a portion of the component extends beyond the groove, through the gap between the flange portions, the flange portions serving to prevent the component from being pulled out of the groove by a transverse relative movement. In a preferred embodiment the longitudinal groove is substantially T-shaped in section, but other shapes are perfectly usable.

Desirably the first face of the element having a longitudinal groove abuts, is adjacent to, or continuous with, the second face of the element which has the substantially smooth surface.

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As mentioned previously, conventional grooved structural elements are substantially rectilinear, and typically have a groove on every face, so that the elements can be used in any orientation. However advantages can be realised by the use of a substantially smooth surface on at least one face of the element.

In particular, when used as part of a door jamb, a hinge component can be inserted into the longitudinal groove on a first face of the element, leaving the smooth second face adjacent to the door. The smooth contour of the second surface means that it is difficult to grip the surface of the door jamb.

As noted above, in preferred embodiments the second surface comprises or consists of a smoothly contoured concave curve. The curved face will conveniently be a section of a circular curve. The radius of curvature will typically be not less than 40 cm, preferably not less than 44 cm, more preferably not less than 48 cm, and most preferably not less than 52 cm.

This is advantageous in situations where young children may use the door and where they may accidentally trap their fingers against the door jamb when the door is closed. Thus the grooved structural element of the invention may be useful in private residential buildings and in public buildings, especially nurseries, primary schools and the like, where young children will be present.

In addition, the element of the invention may be especially useful in detention facilities, such as prison cells, police holding cells, and security vehicles (police or private security firms) used to detain and/or transport detainees. In such situations, especially if under the influence of alcohol and/or drugs, detainees may seek to resist being forcibly introduced into a cell or detention compartment of a security vehicle, and may seek to grab the door jamb with one or both hands. A door jamb having a smooth face, formed by the grooved structural element of the invention, offers very little purchase and so does not assist such persons to resist forcible introduction into a cell or detention facility. It also therefore lessens the chance that such people will have their fingers injured by crushing against the door jamb when the door of the cell or detention compartment is closed.

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The element of the invention may also be useful in architectural applications e.g. in buildings, at the junction of two or more surfaces. Thus, for example, the element could be useful in mating together a wall and a ceiling, or two walls, or a wall and a floor, two ceilings and a wall etc.

It may be advantageous for the element of the invention to comprise a channel, especially a centrally-disposed channel, within which cabling or conduit and the like may be concealed.

It is conceivable that light fittings or similar may be movably mounted within the longitudinal groove of the element.

The grooved structural element of the invention will preferably comprise more than two faces. Thus, for example, the element will comprise a first face having a longitudinal groove therein and a smooth second face (which may preferably comprise or consist of a smoothly contoured concave curve), as aforementioned, and may have a third, fourth, fifth or even a sixth face. One or more of the additional faces may comprised a smooth surface. More preferably however, one or more of the additional faces may comprise a longitudinal groove therein. Advantageously the grooved element will comprise a plurality of faces, each of the plurality of faces having a respective longitudinal groove therein. More especially, the grooved element will preferably comprise three or more faces, each having a respective longitudinal groove therein. In a particular embodiment, the grooved element of the invention will comprise six faces, one face having a smoothly contoured surface, with the other five faces each having a respective longitudinal groove.

In those embodiments in which the grooved element comprises a plurality of longitudinal grooves, the grooves may all be of identical shape and dimensions. More preferably however, the element will comprise at least two different types of groove, which differ in terms of shape and/or dimensions. In a particular embodiment, the element comprises three different types of longitudinal groove.

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In one embodiment described in greater detail below, the element comprises one pair of grooves having a generally T-shaped section and having identical dimensions, and a second pair of grooves, also of generally T-shaped section and having identical dimensions, but of larger size than the first part of grooves. The embodiment has a further groove, also of generally T-shaped section, but of larger dimensions than the second pair of grooves.

It is a further preferred feature that the grooved element of the invention is such that the dimensions of the groove are such as to snugly accommodate the head of a standard ISO metric bolt. Standard ISO metric bolts range from M3 (smallest) to M36 (largest).

For present purposes "snugly accommodate" is intended to refer to two components which can be combined, with a tolerance no greater than about 0.30mm, preferably no greater than about 0.25mm, and more preferably no greater than about 0.20mm.

Conveniently the grooved element will comprise a plurality of grooves (preferably each groove being formed in a different face of the element), each of the plurality of grooves being shaped and dimensioned to snugly accommodate the head of a different standard ISO metric bolt. In one embodiment, the grooved element has a groove which snugly accommodated the hexagonal head of an M6 bolt (thickness 4.15mm, width across flats 5.5mm, width across corners 6.4mm).

In one embodiment the grooved element has a groove which snugly accommodates the hexagonal head of an M8 bolt (thickness 5.6mm, width a/f 13.0mm, width a/c 15.0mm).

In one embodiment the grooved element has a groove which snugly accommodates the hexagonal head of an M12 bolt (thickness 8.18mm, width a/f 19.0mm, width a/c 22.1mm).

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In a preferred embodiment the element has a plurality of grooves, each of the grooves being shaped and dimensioned so as snugly to accommodate, respectively, an M6, an M8 and an M12 hexagonal bolt head.

In preferred embodiments, the grooved element has a plurality of longitudinal grooves which are formed in a respective face of the element, the grooved faces typically being disposed so as to face outwards through an arc of about 270°, so that one or more further components may be inserted into the groove at a selected one of a plurality of positions. In one particular embodiment, the smooth face is positioned between the endmost or outermost two grooved faces and abuts or is continuous with the start of flanged portions extending partially across the mouth of the respective grooves.

In a preferred embodiment, at one or (preferably) both ends of the grooved structural element, there may be one or more tapped holes formed in a core part of the grooved structural element, thereby facilitating the insertion of nuts, screws or other screw-threaded connecting means into the end of the structural element. The one or more tapped holes will desirably be formed along the major axis of the structural element. This will facilitate the formation of the complex multi-component structures comprising one or more grooved structural elements in accordance with the first aspect of the invention.

In a second aspect, the invention provides a multi-component structure, comprising a grooved structural element in accordance with the first aspect of the invention as aforedescribed, in combination with at least a second component, the second component having at least a portion which is engaged with, and retained within, the groove of the structural element.

The grooved structural element may be in combination with a plurality of further components. For example, a first further component may be engaged with a first groove in a first face of the structural element and a second further component may be engaged with a second groove in a different face of the structural element, and so on. In this way complex multi-component structures may be built up to form frames,

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display panels and the like. The further components may be generally planar, e.g. such as a panel, or may be a transverse member or bracing cross-member of a frame, jointed at its opposite end to another grooved structural element in accordance with the first aspect of the invention.

In one particular embodiment, the invention provides a door jamb and a door hinge as a multi-component structure in accordance with the second aspect of the invention. The door jamb is formed by a grooved structural element in accordance with the first aspect. A preferred hinge for use as a second component, with a grooved structural element in accordance with the first aspect, comprises a cylindrical barrel with a projecting solid T-shaped section running longitudinally along the outer surface of the barrel. The projecting T-shaped section is so shaped and dimensioned as to be snugly accommodated with a longitudinal groove of the grooved structural element. Accordingly, the hinge can be inserted into one end of the door jamb by a relative sliding movement longitudinally, which introduced the T-shaped projecting portion on the barrel into the corresponding T-shaped section of the groove in the grooved structural element.

A cylindrical rod or the like is located within the hollow barrel of the hinge, and projects beyond the end thereof. The cylindrical rod preferably comprises at least a surface coating of, or is formed from, a material with a low co-efficient of friction, such as Nylon 6, stainless steel, or phosphor bronze alloys. A second hinge portion, of substantially identical design to the first hinge portion, may be mounted on the end of the cylindrical rod. The T-shaped projecting portion of the second hinge portion is, however, rotated about 180° relative to that of the first hinge portion, and can be used to mount a door thereon. In particular, the door may incorporate along its edge a grooved structural element in accordance with the first aspect of the invention, such that the projecting T-shaped section of the second hinge portion is received within a correspondingly shaped groove in a grooved structural element attached to the door.

The surface of the first structural element, forming the door jamb, adjoining the hinge, is constituted by the smoothly contoured concave or convex face, and the gap between

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the cylindrical barrel of the hinge and the door jamb is too small to allow a person's fingers to obtain a grip.

In a further aspect, the invention provides a cell in a detention facility (e.g. a prison, a police cell etc.), or a detention compartment of a security vehicle (a police van, private security van or the like), having a doorway with a door jamb comprising a grooved structural element in accordance with the first aspect of the invention. The invention also provides a security vehicle having such a detention compartment.

The invention yet further provides a method of making a multi-component structure, the method comprising the step of:

introducing at least a portion of a component into one end of a correspondingly shaped groove of a grooved structural element in accordance with the invention.

The preferred features of the various aspects of the invention will now be described by way of illustrative embodiment and with reference to the accompanying drawings, in which:

Figure 1 is an end elevation of one embodiment of a grooved structural element in accordance with the first aspect of the invention; and

Figure 2 is an end elevation of a hinge component for use in combination with the grooved structural element shown in Figure 1, so as to make a multi-component structure.

Detailed Description of Embodiment

Referring to Figure 1, one embodiment of a grooved structural element in accordance with the invention, denoted generally by reference numeral (2), is formed of extruded aluminium and has a central core (4). Around the periphery of the core (4) are a plurality of faces. At its widest point, the element is about 6.5 cm wide and is about

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2.5 cm deep. The element may be any desired length, but is typically formed in lengths of about 5m.

One face (6) of the element takes the form of a shallow, smoothly-contoured concave surface. Abutting either side of the smooth concave surface (6) are a pair of matching faces (8 and 8'). In each of these faces (8, 8') is formed a generally T-shaped longitudinal groove (9, 9'), at the mouth of which are opposed flange portions (10, 10'), which extend partially across the mouth of the groove. One edge of each pair of flange portions (10, 10') is continuous with the smooth concave surface (6) but disposed at an angle thereto. The pair of faces (8, 8') are disposed at an angle to each other of about 90°, but the faces (8, 8') and the respective T-shaped grooves formed therein are otherwise essentially identical. The T-shaped grooves (9, 9') in the faces (8, 8') are shaped and dimensioned so as snugly to accommodate the hexagonal head of a standard ISO metric M6 sized bolt. Accordingly, a further structural component can be attached to the grooved element (2) by means of such a bolt, the head of which can be introduced into the groove at one end thereof by relative longitudinal sliding movement of the bolt and the grooved structural element.

Adjacent to the faces 8, 8' is a second pair of faces 12,12'. These are similar in shape to faces 8, 8' and also have a T-shaped groove formed therein. The faces 12,12', and the T-shaped grooves therein, are however slightly larger than the faces 8, 8' and the corresponding grooves. The T-shaped grooves in the faces 12,12' are shaped and dimensioned so as to snugly accommodate the hexagonal head of an ISO standard metric M8 sized bolt. The faces 12,12' are formed at an angle of about 90° to the respective adjacent face 8, 8'.

A fifth face (14) is formed between the faces (12,12'). Again, this face is generally similar to the faces (8, 8') and (12,12'), and is formed with a T-shaped groove therein. The face (14), and associated T-shaped groove is however larger than faces (12,12') and their associated grooves, and is shaped and dimensioned so as to snugly accommodate the hexagonal head of an ISO standard metric M12 sized bolt. The face (14) is disposed at an angle of about 45° to each of the faces (12,12').

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Accordingly, a plurality of further components may be attached to the grooved structural element (2) by insertion of a projecting portion (such as a bolt head, or a projecting portion of the further component shaped and dimensioned as to co-operate with one of the T-shaped grooves in the structural element) at one end of the grooves in the structural element and then causing relative sliding movement to engage the element and the further component and place them in the desired relative position.

Within the core (4) of the element are a pair of substantially identical hollow channels 16, separated by a solid bridge piece (17) joining the face (14) and the smooth concave face (4). At the outer end of each channel (16) is a generally circular tapped aperture (18), which can accommodate a screw-threaded attachment such as a screw or bolt.

Referring to Figure 2, a further component is shown, adapted and configured for attachment to the grooved structural element shown in Figure 1.

In Figure 2, the further component, denoted generally by reference numeral (20), is formed from extruded aluminium. The component (20) takes the form of a cylindrical barrel (22) with a hollow circular bore (24) defined within. A projecting T-shaped section (26) runs longitudinally along the outer surface of one side of the barrel (22). The projecting section (26) is adapted and configured to engage with, and be retained within, the correspondingly T-shaped groove in face (8) or (8') of the element shown in Figure 1.

In an embodiment, the grooved structural element shown in Figure 1 can form a multi-component structure with a plurality of further components, one or more being essentially as shown in Figure 2, with which further components may co-operate to act as a door hinge.

For example, a rod (e.g. of metal or durable synthetic plastics material, such as a phosphor bronze alloy or Nylon) - may be accommodated within the barrel (22) of the component (20), and extend therefrom at one or both ends.

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A second component, generally of very similar (preferably identical) design to the component 20, may be mounted on the projecting portion of the rod, but axially rotated through about 180° relative to the first further component (20), such that a T-shaped projecting portion on the second component engages not with the door jamb but with one edge or side of a door. Advantageously the door may comprise a grooved structural element similar to that shown in Figure 1, which facilitates attachment of the door to the second component.

In other embodiments, the second component may comprise one or more screw-treaded openings (typically, but not necessarily) positioned on a T-shaped projection. The screw-threaded openings may accommodate a screw-thread fastening means, such as a screw, by which the door can be attached to the second component.

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Claims

1. A multi-faced grooved structural element having at least one longitudinal groove formed on a first face of the element, and having a second face which has a substantially smooth surface.

2. A structural element according to claim 1, wherein the second face comprises or consists of a smoothly contoured concave curve.

3. A structural element according to claim 2, wherein the concave curve is a section of a circular curve.

4. A structural element according to any one of the preceding claims, comprising a plurality of faces, each of the plurality of faces having at least one longitudinal groove formed therein.

5. A structural element according to any one of the preceding claims, comprising at least one pair of substantially identical faces, each of the pair of faces having a substantially identical longitudinal groove formed therein.

6. A structural element according to any one of the preceding claims, comprising a first pair of substantially identical faces, each of the first pair of faces having a substantially identical groove formed therein, and further comprising a second pair of substantially identical faces, each of the second pair of faces having a substantially identical groove formed therein, the second pair of faces being substantially identical to, or different from, the first pair of faces.

7. A structural element according to any one of the preceding claims, comprising a core which is at least partly hollow.

8. A structural element according to any one of the preceding claims comprising a plurality of faces, each having a longitudinal groove formed therein, the plurality of faces projecting outwards from the element through an arc of about 270°.

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9. A structural element according to any one of the preceding claims, comprising a plurality of longitudinal grooves, each groove being shaped and dimensioned to snugly accommodate the head of a metric ISO standard bolt.

10. A structural element according to claim 9, having a longitudinal groove shaped and dimensioned to snugly accommodate the head of a metric ISO standard bolt selected from the group consisting of M6, M8 and M12.

11. A structural element according to claim 9 or 10, comprising at least three faces, each face being formed with a longitudinal groove therein, one of the grooves being shaped and dimensioned to snugly accommodate the head of an M6 bolt, one of the grooves being shaped and dimensioned to snugly accommodate the head of an M8 bolt, and one of the grooves being shaped and dimensioned to snugly accommodate the head of an M12 bolt.

12. A structural element according to any one of the preceding claims, comprising at least one tapped hole at one or both ends of the element, to receive a screw-threaded connecting means.

13. A multi-component structure, comprising a grooved structural element in accordance with any one of the preceding claims, in combination with at least a second component having a portion which is engaged with, and retained within, the groove in the grooved structural element.

14.

A cell in a detention facility, or a detention compartment of a security vehicle, comprising a multi-component structure according to claim 13.

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A security vehicle, especially a police van, comprising a multi-component structure according to claim 13.

A method of making a grooved structural element according to any one of claims 1-11, the method comprising the step of forming a structural element having at least one longitudinal groove in a first face thereof, and having a second face which is substantially smooth and which face comprises or consists of a smoothly contoured concave curve.

A method of making a multi-component structure according to claim 12, the method comprising the step of introducing at least a portion of one component into one end of a correspondingly shaped groove of a grooved structural element according to any one of claims 1-11.

A grooved structural element substantially as hereinbefore described and as shown in the accompanying drawings.

14 A multi-component structure according to claim 13, wherein a grooved structural element in accordance with any one of claims 1-12 forms, or is comprised within, a door jamb, and a door hinge component is engaged with, and retained within, the groove in the grooved structural element.

15. A cell in a detention facility, or a detention compartment of a security vehicle, comprising a multi-component structure according to claim 14.

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16. A security vehicle, especially a police van, comprising a multi-component structure according to claim 14.

17. A method of making a grooved structural element according to any one of claims 1-12, the method comprising the step of forming a structural element having at least one longitudinal groove in a first face thereof, and having a second face which is substantially smooth.

18. A method of making a multi-component structure according to claim 13, the method comprising the step of introducing at least a portion of one component into one end of a correspondingly shaped groove of a grooved structural element according to any one of claims 1-12.

19. A grooved structural element substantially as hereinbefore described and as shown in the accompanying drawings.

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Claims

1. A multi-faced grooved structural element having at least one longitudinal groove formed on a first face of the element, and having a second face which has a substantially smooth surface and which face comprises or consists of a smoothly contoured concave curve.

2. A structural element according to claim 1, wherein the concave curve is a section of a circular curve.

3. A structural element according to claim 1 or 2, comprising a plurality of faces, each of the plurality of faces having at least one longitudinal groove formed therein.

4. A structural element according to any one of the preceding claims, comprising at least one pair of substantially identical faces, each of the pair of faces having a substantially identical longitudinal groove formed therein.

5. A structural element according to any one of the preceding claims, comprising a first pair of substantially identical faces, each of the first pair of faces having a substantially identical groove formed therein, and further comprising a second pair of substantially identical faces, each of the second pair of faces having a substantially identical groove formed therein, the second pair of faces being substantially identical to, or different from, the first pair of faces.

6. A structural element according to any one of the preceding claims, comprising a core which is at least partly hollow.

7. A structural element according to any one of the preceding claims comprising a plurality of faces, each having a longitudinal groove formed therein, the plurality of faces projecting outwards from the element through an arc of about 270°.

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8. A structural element according to any one of the preceding claims, comprising a plurality of longitudinal grooves, each groove being shaped and dimensioned to snugly accommodate the head of a metric ISO standard bolt.

9. A structural element according to claim 8, having a longitudinal groove shaped and dimensioned to snugly accommodate the head of a metric ISO standard bolt selected from the group consisting of M6, M8 and M12.

10. A structural element according to claim 8 or 9, comprising at least three faces, each face being formed with a longitudinal groove therein, one of the grooves being shaped and dimensioned to snugly accommodate the head of an M6 bolt, one of the grooves being shaped and dimensioned to snugly accommodate the head of an M8 bolt, and one of the grooves being shaped and dimensioned to snugly accommodate the head of an M12

C\| bolt.

CD 11. A structural element according to any one of the preceding claims, comprising at least

^ one tapped hole at one or both ends of the element, to receive a screw-threaded

O connecting means.

12. A multi-component structure, comprising a grooved structural element in accordance with any one of the preceding claims, in combination with at least a second component having a portion which is engaged with, and retained within, the groove in the grooved structural element.

13. A multi-component structure according to claim 12, wherein a grooved structural element in accordance with any one of claims 1-11 forms, or is comprised within, a door jamb, and a door hinge component is engaged with, and retained within, the groove in the grooved structural element.