Modular architectural structure for playground and the like

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Patent issued

01/12/1993

Inventor(s):	Frankel, Arie
Assignee	American Playtime Systems, Inc. (Melville, NY)
Application	No. 07/688,994 filed on 04/25/1991
Current US Class	482/35, 472/116, 472/136, 472/137
Field of search	472/116, 472/118, 482/35, 52/648, 52/DIG.10
International Classes:	E04H 1200
Examiners
Primary	Chilcot, Jr. Richard E.
Attorney, agent or firm:	Kane, Dalsimer, Sullivan, Kurucz, Levy, Eisele and Richard
US patent references	2956806, 3632109, 3949985, 4301766, 4369965
Foreign patents	1391218 (03/31/1975, GB)

An architectural structure is made of one or more walls, each wallconsisting of a lattice of rigid cells hingedly interconnected andsupported by frame members. The cells may have holes sized and constructedto make the walls suitable for playground equipment.
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RELATED APPLICATIONS
This is a continuation-in-part to application Ser. No. 521,139, filed May8, 1990, now U.S. Pat. No. 5,137,271.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention pertains to a novel modular structure for use onplaygrounds, and other wall-type structures such as fencing and so on, andmore particularly to a structure consisting of several relatively flatcells having a preselected geometric shape which are hingedlyinterconnected.
2. Brief Description of the Prior Art
Typically, playgrounds or other areas dedicated for children's activitiesinclude structures adapted for climbing. These structures are made eitherof metal bars, such as the well known monkey bars, or are cementstructures. However, these structures are usually unsafe and thousands ofserious injuries occur every year.
Other structures have been proposed to replace the ones presently in usebut with relatively little success. For example, a net-like structurecomposed of circular plastic rings interconnected by straps is shown onpage 14 of the Jun. 4, 1988 edition of the Israeli magazine Maariv.However, this structure is unsafe because it has holes of sizes and shapeswhich may entrap a child's head, hand, or foot. Other proposedarchitectural structures are shown in U.S. Pat. No. Des. 218,455; U.S.Pat. Nos. 3,974,611; 2,956,806; 4,603,853; and 3,970,301. However, nonethese structures are acceptable because they are unsafe. Furthermore, thestructures shown in the above-mentioned references are two complicated andexpensive to make, and are often unsuitable for outdoor installations.
SUMMARY OF THE INVENTION
In view of the above-mentioned disadvantages of the prior art it is anobjective of the present invention to provide a structure which can besafely installed and used thereby avoiding crippling, and fatal injuries.
A further objective is to provide a modular structure which can be used invirtually an infinite number of configurations.
Yet another objective is to provide a structure which can be formed intoaesthetically pleasing and colorful configurations so they are attractiveto children.
Yet a further objective is to provide a modular structure which is made ofmaterials which are safe for use by children, yet strong enough towithstand the natural elements whereby the structures can be installedoutdoors.
Another objective is to provide a modular structure which is made ofrelatively inexpensive materials, and which can be easily assembled intovarious configuration on site.
Other objectives and advantages of the invention will become apparent formthe following description for the invention. An architectural structureconstructed in accordance with this invention includes one or more walls,each wall consisting of a rigid frame, a plurality of flat rigid cells,and flexible hinge means for interconnecting said cells or connecting saidcells to the frame so that there is no substantial space lefttherebetween, to avoid entrapping a child's head or limbs. The cells arepreferably made of a high density plastic material capable of withstandingnatural forces including wide temperature swings, wind, humidity, snow orrain without degradation. The hinges ar preferably made of a nylon orother flexible material and are imbedded in the cells to reduce exposureto the elements or to vandalism.
In an alternate embodiment, the cells are made with matching male andfemale interconnecting members fitting into each other. Theinterconnecting members are perforated to allow adjacent cells to becoupled by hinging pins.

What is claimed is:
1. A modular architectural structure comprising:
a wall including:
a plurality of flat cells made of a rigid material;
a supporting frame defining a preselected shape for said wall; and
flexible coupling means for coupling each cell to an adjacent cell and tosaid supporting frame, said cells being constructed and arranged to leavesubstantially no space between adjacent cells in said wall.
2. The structure of claim 1 wherein said flexible coupling means comprisesmale and female intergaging members provided on said cells, and connectingmeans for connecting at least one male members of one cells to at leastone female member of an adjacent cell.
3. The structure of claim 1 wherein each said cell includes a hingeengaging means for engaging said flexible hinge means.
4. The structure of claim 1 wherein each said cell includes a peripheralmember surrounding a hole.
5. An architectural structure comprising:
a. a plurality of rigid flat cells consisting of a peripheral memberdefined by a plurality of linear outer edges;
b. a plurality of hinge means, each hinge means being disposed between theedges of two adjacent cells; and
c. support frame means coupled to some of said cells for support.
6. The structure of claim 5 wherein said hinge means comprises male andfemale interconnecting members provided on said cells and coupling meansfor coupling interconnecting means of adjacent cells.
7. The structure of claim 5 wherein said peripheral member includes hingecoupling means for coupling said cells to said hinges.
8. The structure of claim 5 wherein said peripheral member includes channelmeans, and said hinge means includes a first portion and a second portion,said first and second portions being captured by the channel means of acorresponding cell.
9. The structure of claim 5 wherein said hinge means is extensible.
10. The structure of claim 5 wherein said support means includes aplurality of rigid tubes, corners for interconnecting said tubes andsupport hinge engaging means for engaging said hinge means.
11. An architectural structure comprising:
a plurality of interconnected walls; each wall consisting of a rigid framewith frame hinge engaging means;
a plurality of first rigid cells, each first cell having a peripheral framedefined by linear edges and cell hinge engaging means disposed at saidlinear edges;
a first set of hinges for coupling said first cells, each said first hingesbeing engaged by the cell hinge engaging means of two adjacent firstcells; and
a second set of hinges for coupling some of said first cells to said rigidframe, each said second hinge being disposed between a cell hinge engagingmeans and a frame hinge engaging means.
12. The structure of claim 11 wherein said cell hinge engaging meansincludes a throughhole disposed in parallel with a corresponding linearedge.
13. The structure of claim 12 wherein said throughhole includes stop meansfor frictionally engaging said hinges.
14. The structure of claim 11 wherein said frame hinge engaging meanscomprises a channel disposed on said frame with a longitudinal openingdirected toward said first cells.
15. The structure of claim 11 wherein said first and second hinges eachincludes a first and a second cylindrical portion for capture by saidhinge engaging means, and a hinge web extending between said first andsecond portions.
16. The structure of claim 11 wherein said first cells ar made of ahigh-density plastic.
17. The structure of claim 11 further comprising a plurality of secondcells arranged and hingedly coupled between some of said first cells andsaid frame, said second cells having a geometric shape different from saidfirst cells.
18. The structure of claim 11 wherein said hinges are made of nylon.
19. The structure of claim 17 wherein said hinges are made of nylonreinforced in one direction by fiberglass.
20. The structure of claim 11 wherein said hinge means includes a notchformed along an edge of cell, a hole made in said cell along said oneedge, a tongue formed along another edge of another cell sized andarranged to fit into said notch, and a pin for connecting said one celland said another cell by passing through said tongue and said hole.

BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a plan view of a basic cell used in a structure constructed inaccordance with this invention;
FIG. 2 shows a side view of the cell of FIG. 1;
FIG. 3 shows a sectional view of the cell of FIG. 1 taken along lines 3--3in FIG. 1;
FIG. 4 shows a partial sectional view of the cell taken along line 4--4 inFIG. 3;
FIG. 5 shows an isometric view of a hinge used to interconnect cells inaccordance with this invention;
FIG. 6 is a cross-sectional view of a cell connected to a frame member;
FIG. 7 shows an elevational view of a modular structure constructed inaccordance with this invention;
FIG. 8 shows an elevated view of a cylindrical structure constructed inaccordance with this invention;
FIG. 9 shows a plan view of an alternate embodiment for the cell; and
FIG. 10 shows a side-sectional view of the cell of FIG. 9 taken along line10--10.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the Figures, and more particularly to FIGS. 1-4, amodularity of the inventive structure described herein is provided by abasic cell which may be interconnected with other cells to produce a wallmember of any desired shape and dimension for a modular structure. Atypical basic cell 10 as shown in the Figures is generally flat (i.e. itsoverall length and width are much greater then its depth). The cell 10 mayhave any geometric shape, but preferably a shape should be selected whichwould permit several cells to be interconnected to form a large wall withsubstantially no holes therebetween which may entrap a child's head orlimbs. In FIG. 1 cell 10 is shown to be generally hexagonal because thisconfiguration can be used to construct a large number of differentstructures, however, the cell may also be square, rectangular, triangular,pentagonal, and so on. Preferably, all the edges of the cell are roundedto eliminate the risk of cuts and scratches. The cell 10 consists of aperipheral hexagonal member 12 with a substantially circular cross sectionas shown. Member 12 is defined by six straight edges 14. (Of course thenumber of edges 14 for each cell 10 depends on its geometric shape).Preferably, where two edges 14 meet, the cell 10 is rounded, as at corner16. Member 12 is formed with circular throughholes 18, each throughhole 18being disposed substantially in parallel with a corresponding edge 14 at adistance W as shown in FIG. 4. Each throughhole 18 is open toward an edge14 by a channel 20. Adjacent to corner 16, each channel 20 is defined bytwo parallel walls 22, 24 formed in member 12 and separated by a distanceA so that the channel has a uniform cross-sectional radial dimensiontherebetween. However, the channel also has a central section 20' definedby two walls 26, 28 extending somewhat at angular, or radially withrespect to the axis of throughhole 18. At the edges bordering on hole 18,the tangential or peripheral distance between walls 26, 28 issubstantially equal to dimension A defined above. In the region defined bywalls 26, 28, channel section 20' has a cross sectional dimension whichincreases radially outward as shown in FIG. 3. At the two longitudinalends of walls 26, 28, throughholes 18 are formed with two ramps 30, 32 asshown in FIG. 4.
Cell 10 further includes a web 34 extending inwardly from member 12. Web 34may be continuous, or it may be formed with a substantially circular hole36. The inner edge 38 defining hole 36 is preferably rounded as shown inFIG. 3.
The inventive structure also includes a plurality of hinges such as hinge40 shown in FIG. 5. This hinge 40 consists of two cylindrical portions 42,44 arranged substantially in parallel. The portions 42, 44 have a smallerdiameter then the diameter of throughholes 18 in cell 10, and a lengthwhich is equal to or slightly smaller than the longitudinal distancebetween ramps 30, 32 shown in FIG. 4. Portions 42, 44 are connected by acoextensive hinging section 46 which is relatively flat, and which has athickness slightly smaller than dimension A. Laterally, the distancebetween portions 42, 44 exceeds twice dimension W.
Hinge 46 may be used to couple a cell 10 to another cell or to a stationaryframe. For example, FIG. 6 shows a stationary frame member 48 consistingof an elongated hollow tube 50 with a channel shaped member 52. Member 52is secured to tube 50 by a weld 54, by an adhesive, or any otherwell-known means. Member 52 has a lateral opening 56. A cell 10 is securedto member 48 as follows. First one portion 42 is inserted into channelmember 52 with the hinge web 46 extending through opening 56. A cell 10 isthen mounted on hinge 40 by throughhole 18 until it passes one of theramps, such as ramp 30 passes the hinge 40. The ramps 30, 32 and the innerwall of throughhole 18 are sized and arranged to capture a hinge 40whereby once the a hinge is inserted therebetween an interference fit isformed between the ramps and the hinge thereby making it difficult toseparate the hinge 40 from cell 10. Of course, a cell 10 may be secured toidentical cell 10 in a similar manner Importantly, because walls 26, 28are disposed at an angle, they allow relative angular movement between acell and frame member 48, or another cell 10. Furthermore, hinge 40 may bemade of a relatively flexible and a somewhat extendible or elasticmaterial to permit adjacent cells 10 interconnected by hinges 40 to flex,as well as, to pivot slightly relative to each other.
FIG. 7 shows how a modular wall 60 may be made of a plurality of cells 10interconnected by hinges 40 and supported by a plurality of frame members48. The frame members may be interconnected at the corners by corner balls60. Furthermore, some of the lower corner balls may be mounted onstationary support such as a post 62 fully or partially buried in theground 66. Preferably, at the interface between a frame member 48 andbasic cells 10, a second half-hexagonal cell 64 or a triangular cell 64'may be used as shown in FIG. 7 to eliminate holes which may trap a child'slimb or head. Cells 64, 64' are formed with channel means for engaginghinges as described above. Several planar walls such as the wall shown inFIG. 7 may be interconnected to make any shape desired. Furthermore,curved walls may also be formed to form cylindrical shapes as shown inFIG. 8 or any other shapes as desired.
It will be apparent to one skilled in the art that the modular structuredescribed above can be used to make architectural objects of virtuallyinfinite configurations. Objects used in playgrounds may be created byseveral walls formed as shown in FIG. 7, with the holes 36 being used bychildren as foot and hand supports. The flexibility provided by the hingesgives each wall or structure a semi-flexible feel similar to a rope net.Other architectural structures such as fences, gazebos, and so on may bemade in a similar manner. For these structures, holes 36 need not becircular or may be omitted completely. The cells 10, frame members 48, andhinges 40 may be shipped separately and assembled at the site.
Preferably each basic cell 10 (and cell 64) is made of high impact, highdensity polypropylene material which resists wear and tear, and is notcorroded or otherwise degraded even when exposed to wind, rain, snow, sun,salty air and so on. Each cell may be made for example by molding. Ifnecessary, two substantially identical sections may be molded separatelyand joined by sonic welding to form a single, unitary cell 10. Preferably,hinge 40 is made of an elastic material such as nylon. The nylon may bereinforced by fiberglass strands especially in the area of the web toresist tearing. It should be noted that since most of the nylon hinges aredisposed inside throughholes 18, they will be protected from the elementsor vandalism by the cells 10 or channels 52. The cells can have any shapeor size. For example, a hexagonal cell may have an overall length andwidth in the range of 5/16" and a thickness in the range of from 1/2" to11/2".
Frame members 48 with channel members 52 may be made of metallic materialsuch an aluminum or aluminum alloy made, for example, by extrusion. Forinstallations exposed to extreme weather conditions, such as the seashore, the frame members are preferably galvanized or otherwise coatedwith a protective layer.
FIG. 8 shows a cylindrical structure constructed in accordance with thisinvention including two uprights 70, 72 and hoops 74, 76 supporting aplurality of interconnected cells 78.
In a somewhat preferred embodiment of the invention, shown in FIGS. 9 and10, the cells 100 are made with one or more notches 102 on sides 106 and108. Sides 110 and 112 are provided with tongues 104 shaped to fit intonotches 102. In addition, sides 106 and 108 are provided with throughholes 114 which open into notches 102. Tongues are also provided withthrough holes 116. Cell 100 is formed with a central round opening 120 asin the other embodiment. The sides of the cell 100 are rounded as shown inFIG. 10 to prevent cuts and bruises. While cell 100 in the Figures issquare, other geometric shapes may also be provided for the cell.
The notches 102, tongues 104 and holes 114, 116 are shaped and arranged sothat one cell 100 can be fit together with a similar cell 100' shown inFIG. 9 in phantom lines so that tongues 104' fit into notches 102 as cell100' is advanced toward cell 100 in the direction indicated by arrow A.When the tongues 104' are seated in notch 102, along side 108 hole isaligned with holes 116'. The two cells then may be coupled by inserting arigid pin 122 therethrough. Another pin 124 may be used to couple cell 100to yet another cell. Pins 122, 124 are preferably stainless steel. Variousstructures for a playground may be obtained by coupling a plurality ofcells in this manner. The notches 102 and tongues 104 may also be used tomount the cells on a stationary frame. Obviously numerous modificationsmay be made to the invention without departing from its scope as definedin the appended claims.