Field of the invention

[0001] The present invention relates to systems for connecting an accessory to a mounting arm. The invention has primarily developed for use in connecting an accessory such as, for example, a spigot of a street light assembly to a light mounting arm extending from support structure (e.g. light pole) having a base and a mast held therein.

[0002] It should be appreciated, however, that various forms of the invention are not limited to this particular field of use, being potentially applicable to a wide range of industrial applications where joining of various accessories and component parts to a mounting arm is required.

Background of the invention

[0003] The following discussion of the prior art is intended to frame the invention in an appropriate technical context and allow the associated advantages to be more fully understood. It should be appreciated, however, that any references to prior art should not be construed as an express or implied admission that such art, or any associated disadvantages or limitations, are widely known or part of common general knowledge in the field.

[0004] In the field of elongated support structures and in particular street poles or lighting, there have been significant changes made in the manufacture and instalment of such street and outdoor lighting poles.

[0005] Previously, support structures for street lighting etc. were constructed from timber or as a unitary steel tubular body. Architectural design and aesthetic demand has led to the development of a wide range of options for such street lighting.

[0006] With urban designers requiring the need for pole mounted lighting, traffic control, CCTV, banners, signage, public warning, communication, environmental monitoring, pedestrian management and many other applications in public areas it was inevitable that a streetscape would become cluttered with a myriad of different poles delivering these services. Not only has this become visually unsatisfactory in many places but also it has created a maze of obstructions in pedestrian areas using up valuable civic space. [0007] This has a new generation of light poles that delivers to the community an effective solution to the growing number of single purpose poles that are sprouting in the urban environment.

[0008] In particular the applicant has developed its Multipole™ and Multipole Solar™ products that deliver an aesthetically pleasing all aluminium multi-function pole that can provide a flexible secure home for many of the services required in the streetscape. In addition the poles can be the basis for the provision of public amenities such as bike racks, bus shelters, water bubblers and seats.

[0009] Early generations of these poles relied on a steel core clad in aluminium decorative cladding however recent developments have removed any reliance on steel by designing a pole based on the applicant’s own extrusion technology.

[0010] This provides a number of significant advantages including improves sustainability since aluminium poles have a smaller carbon footprint, reduce installation costs as the weight of aluminium poles is substantially less than steel poles and the composite arrangement of producing the pole in separate connectable tubes reduce transport costs, low maintenance costs and resistance to graffiti, a safer pole due to its inherent energy absorbing nature of aluminium as compared with steel, excellent strength and ability to withstand severe environmental conditions, aesthetic advantages since there are no welded joints in the extruded aluminium pole section (such welded joints also provide a weakness in conventional steel poles) as well as the ability to produce tracks or channels in the aluminium extrusion to allow installation of accessories at various heights over the pole.

[0011] In one particular embodiment, the poles may be made from a series of connectible or extrusion tubes, eg. at least two. Generally the lower larger cross-section tube acts as a base and is embedded or connected to the substrate or foundation with a small tube or “mast” nesting therein. The smaller or upper tube may then be raised to the desired height. Generally a permanent fixing arrangement is provided by means of bolts, fasteners or similar extending through the outer edge of the base tube into the mast to ensure they are held in the appropriate "final" position. However, such an arrangement is expensive and timely to install. Drilling of holes, insertion of appropriate fasteners etc. is difficult.

[0012] It is an object of the invention to overcome or substantially ameliorate one or more of the disadvantages or limitations of the prior art, or at least to provide a useful alternative. Summary of the invention

[0013] According to one aspect of the present invention, there is provided a method of joining a first element and a second element, the method including: inserting at least a portion of the second element into an end of the first element; and applying a force to at least one discrete location on an outer surface of the first element to create a region of localised deformation in the first element, wherein the region of localised deformation in the first element causes a corresponding region of localised deformation in the second element, thereby to prevent relative movement between the first element and the second element.

[0014] The manner in which the region of localised deformation in the first element forms the corresponding region of localised deformation in the second element may be such that the resulting engagement therebetween acts to prevent relative linear (e.g. sliding, translational or telescopic) movement between the first element and the second element. The manner in which the region of localised deformation in the first element forms the corresponding region of localised deformation in the second element may be such that the resulting engagement therebetween acts to prevent relative rotational movement between the first element and the second element. The manner in which the region of localised deformation in the first element forms the corresponding region of localised deformation in the second element may be such that the resulting engagement therebetween acts to prevent both relative linear and rotational movement between the first element and the second element.

[0015] In some embodiments, the method includes applying the force to the outer surface of the first element in two or more discrete locations. In some embodiments, the method includes applying the force on the outer surface of the first element in two or more discrete locations such that the regions of localised deformation are arranged in a predetermined pattern. The pattern may be a regular or irregular pattern.

[0016] In some embodiments, the method includes applying the force on the outer surface of the first element so as to form one or more pairs of regions of localised deformation. In some embodiments, the regions of localised deformation in the or each pair of regions of localised deformation are aligned. Preferably, the regions of localised deformation in the or each pair of regions of localised deformation are arranged on opposite sides of the first element by applying the force in opposite directions along a common axis. [0017] In some embodiments, the method includes applying the force on the outer surface of the first element so as to form a first pair of regions of localised deformation in which the regions are formed on opposite sides of the first element and aligned along a first common axis, and a second pair of regions of localised deformation in which the regions are formed on opposite sides of the first element and aligned along a second common axis. Preferably, the first common axis is offset from (e.g. rotated relative to) the second common axis. In some embodiments, the first common axis extends orthogonally to the second common axis.

[0018] In some embodiments, the method includes applying the force to the or each discrete location on the outer surface of the first element such that the associated region of deformation in the first element is formed as a first dimple. Preferably the method includes applying each force to the first element in a radial direction; e.g. in a direction orthogonal to the longitudinal axis of the first element. Preferably, the force is applied such that the or each first dimple extends inwardly towards a central (longitudinal) axis of the first element.

[0019] In some embodiments, due to the application of the force, the deformation of the first element to form the first dimple simultaneously forms a second dimple in the second element, particularly the portion of the second element that is received in the first element. This is a particularly advantageous feature of the method disclosed herein. It will be appreciated that the process of simultaneously forming complementary first and second dimples in a pair of elements provides a very simple, efficient and effective means for securely and permanently fastening the two elements together. Such a process obviates the need for exact measurements for drilling or otherwise forming fastening locations, undertaking relatively slow and time-consuming drilling processes and subsequently inserting and locking fastening elements to secure two elements togethers. Similar advantages apply over other fastening methods such as for example welding processes. It will therefore be readily appreciated by those skilled in the art that the method disclosed herein is significantly faster than existing methods and provides significant associated cost savings.

[0020] The deformation in both the first element and the second element (which forms the respective first and second dimples) is plastic deformation. The method may include applying the force such that the first dimple has a predetermined depth, wherein the depth of the first dimple is greater than the second dimple. In this way, the outer surface of the first dimple is complementary in profile to the inner surface of the second dimple. The outer surface of the first dimple may be convex. The inner surface of the second dimple may be concave. [0021] In some embodiments, the first element is elongate. In some embodiments, the first element is cylindrical. In some embodiments, the first element is hollow. In some embodiments, the first element has a hollow bore associated with at least one end. Preferably, the first element is formed of a ductile material, preferably a metal such as, for example, aluminium, copper, steel, etc.

[0022] In some embodiments, the second element is elongate. In some embodiments, the second element is cylindrical. In some embodiments, the second element is hollow. In some embodiments, the second element has a hollow bore associated with at least one end. Preferably, the second element is formed of a ductile material, preferably a metal such as, for example, aluminium, copper, steel, etc.

[0023] In some embodiments, the first element is a hollow, cylindrical tube having a generally annular cross-sectional profile, and the second element is a hollow, cylindrical tube having a generally annular cross-sectional profile, wherein the first element has an inner diameter which is greater than an outer diameter of the second element such that at least a portion of the second element can be received in an end of the first element.

[0024] In some embodiments, the first element and the second element are configured such that the second element is close-fittingly received within the first element. In some embodiments, the first element and the second element are configured such that the difference between the inner diameter of the first element and the outer diameter of the second element is predetermined. In certain embodiments, the difference between the inner diameter of the first element and the outer diameter of the second element is less than 10.0 mm, preferably less than 5.0 mm, more preferably less than 2.5 mm, and more preferably still less than 1 .5 mm.

[0025] In some embodiments, the first element may have an outer diameter in the range between around 20 mm to 120 mm. In certain preferred embodiments, the outer diameter of the first element may be about 50 mm, 60 mm, 70 mm, 80 mm or 90 mm. In some embodiments, the first element may have a wall thickness in the range between around 1 .0 mm to 5.0 mm. In certain preferred embodiments, the wall thickness of the first element may be about 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0mm, 4.5 mm or 5.0 mm.

[0026] In some embodiments, the second element may have an outer diameter in the range between around 15 mm to 119 mm. In certain preferred embodiments, the outer diameter of the second element may be about 45 mm, 55 mm, 65 mm, 75 mm or 85 mm, ± 5.0 mm. In some embodiments, the second element may have a wall thickness in the range between around 1.0 mm to 5.0 mm. In certain preferred embodiments, the wall thickness of the first element may be about 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0mm, 4.5 mm or 5.0 mm.

[0027] In some embodiments, the method includes providing a tool for applying the force to the outer surface of the first element, and bringing the tool into engagement with the outer surface to create the region of localised deformation (e.g. the first dimple) in the first element.

[0028] In some embodiments, the method includes driving the tool into and out of engagement with the first element pneumatically or hydraulically. In some embodiments, the method includes actuating the tool according to a semi-autonomous or autonomous control methodology.

[0029] In some embodiments, the method includes providing a jig for positioning the first and second elements and holding the first element and second element during the step of applying the force to the outer surface of the first element. In some embodiments, the jig may include a receiving formation for receiving at least a portion of the first element and/or the second element. The receiving formation may complement or at least partially complement the outer profile or at least a portion of the outer profile of the first element and/or the second element.

[0030] In some embodiments, the method is employed for connecting various elements that will be attached to a street pole such as, for example, to a mast of a light or telegraph pole. In one particular application, the method disclosed herein is particularly advantageous for connecting an accessory (e.g. a street light assembly) having a second element in the form of a spigot extending therefrom to the distal end of first element in the form of a mounting arm (e.g. light arm), wherein the mounting arm is intended to be connected to the mast via its distal end. However, it will be appreciated that the method disclosed herein is not intended to be limited to such applications, and could be readily used for joining other components including for example joining larger components such as modular sections of the mast of a street pole, or a mast to a base. Again, the method is not limited to such exemplary applications.

[0031] According to another aspect of the invention, there is provided an assembly, including: a first element having a receiving formation; a second element at least partially received within the first element; wherein the first element has at least one region of localised deformation which is cooperating with a complementary and corresponding region of localised deformation in the second element such that relative movement between the first element and the second element is prevented.

Brief description of the drawings

[0032] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which

[0033] Figures 1A-1C respectively show perspective, top and side views of an embodiment of assembly of two pipe sections joined together via the method disclosed herein; and

[0034] Figure 2 is a cross-sectional side view of the assembly of Figure 1 showing details of the regions of localised deformation which join the two pipe sections together.

Preferred embodiment of the invention

[0035] Referring to the drawings, the invention provides a method of joining a first element and a second element to form an assembly 1 . The method may be used to join a variety of elements together to form a secure, fixed connection therebetween. Accordingly, it will be appreciated that the method is not limited to the exemplary embodiment or application of the method described below.

[0036] In certain embodiments, the method can be employed for connecting various elements intended to be attached to a street pole such as, for example, to a mast of a light or telegraph pole. By way of example only, the method will be described in relation to the application of joining a first element in the form of a mounting arm 2 to a second element in the form of a spigot 3 extending from an accessory in the form of a street light unit (not shown), thereby to form a light arm assembly 1. The spigot 3 extending from the accessory is connected to the distal end of mounting arm 2, and the mounting arm is intended to be connected to the mast via its distal end.

[0037] In the illustrated embodiment, the mounting arm 2 is in the form of an elongate hollow, cylindrical pipe section having a length ‘L’, an annular cross-sectional area of a predetermined wall thickness T and an inner diameter ‘ID’. The mounting arm 2 is formed of a ductile material, preferably a metal such as, for example, aluminium, copper, steel, etc.

[0038] The spigot 3 is in the form of a hollow, cylindrical pipe section having a length T, an annular cross-sectional area of a predetermined wall thickness ‘t’ and an outer diameter OD’. The spigot 3 is formed of a ductile material, preferably a metal such as, for example, aluminium, copper, steel, etc.

[0039] The inner diameter ‘ID’ of the mounting arm 2 is greater than the outer diameter OD’ of the spigot 3 such that at least a portion of the spigot 3 can be received within the mounting arm 2.

[0040] In the illustrated embodiment, the mounting arm 2 and spigot 3 are configured such that the spigot 3 is close-fittingly received within the first element. For example, the mounting arm 2 may have an outer diameter of 60 mm, and a wall thickness of 2.0 mm. The spigot 3 may have an outer diameter of about 57 mm such that an annular spacing thickness of about 1 .0 mm is provided between the inner surface 4 of the mounting arm 2 and the outer surface 5 of the spigot 3.

[0041] To join the mounting arm 2 and the spigot 3, the proximal end of the spigot 3 is inserted into the distal end of the mounting arm 2.

[0042] A jig (not shown) may be provided for holding the mounting arm 2 and spigot 3 in a desired position and orientation during the joining process. In some forms, the mounting arm and spigot may remain in the same position and orientation within the jig throughout the joining process. In some forms, the mounting arm and spigot may be repositioned such as for example, by rotation, at various stages throughout the joining process to assist in completing the joining process.

[0043] The method includes applying a concentrated or localised force to the outer surface 6 of the mounting arm 2. The force is applied at one or more discrete locations on the outer surface 6 of the mounting arm 2 to create a region of localised deformation 7 in the mounting arm 2. The or each region of localised deformation 7 in the mounting arm 2 causes a corresponding region of localised deformation 8 in the spigot 3, thereby to prevent relative movement between the mounting arm and spigot. [0044] The manner in which the region of localised deformation 7 in the mounting arm 2 forms the corresponding region of localised deformation 8 in the spigot 3 is such that the resulting engagement therebetween acts to prevent both relative linear (e.g. sliding, translational or telescopic) and rotational movement between the mounting arm and spigot.

[0045] In the illustrated embodiments, the method includes applying the force to the outer surface of the mounting arm 2 in four discrete locations 7. In the illustrated embodiment, the regions of localised deformation are arranged in a regular pattern, with two pairs of aligned regions arranged on opposite sides of the mounting arm 2.

[0046] In other embodiments, it is preferred that at least one region of deformation arranged on a first axis, and at least one region of deformation arranged on a second axis which extends orthogonally to the first axis.

[0047] The method includes applying the force to the or each discrete location on the outer surface 6 of the mounting arm 2 such that the associated region of deformation 7 is formed as a first dimple. To achieve this, the method preferably includes applying each force to the mounting arm 2 in a radial direction; e.g. in a direction orthogonal to the longitudinal axis of the mounting arm. As clearly shown in Figure 2, the force is applied such that the or each first dimple extends inwardly towards a central (longitudinal) axis of the mounting arm.

[0048] The deformation in both the mounting arm 2 and spigot 3 (which forms the respective first and second dimples) is permanent or plastic deformation. The method may include applying the force such that the first dimple has a predetermined depth, wherein the depth of the first dimple is greater than the second dimple. In this way, the outer surface of the first dimple is complementary in profile to the inner surface of the second dimple. The outer surface of the first dimple may be convex. The inner surface of the second dimple may be concave.

[0049] The method includes providing a tool (not shown) for applying the force to the outer surface of the mounting arm 2, and bringing the tool into engagement with the outer surface to create the region of localised deformation 7 (e.g. the first dimple) in the mounting arm. The method preferably includes driving the tool into and out of engagement with the mounting arm via pneumatically or hydraulically operated actuator (not shown). The tool may be operated under a semi-autonomous or autonomous control methodology. [0050] As foreshadowed, due to the application of the force, the deformation of the mounting arm to form the first dimple simultaneously forms a complementary second dimple in the spigot 3. This is a particularly advantageous feature of the method disclosed herein. It will be appreciated that the process of simultaneously forming complementary first and second dimples in a pair of elements provides a very simple, efficient and effective means for securely and permanently fastening the two elements together. Such a process obviates the need for exact measurements for drilling or otherwise forming fastening locations, undertaking relatively slow and time-consuming drilling processes and subsequently inserting and locking fastening elements to secure two elements togethers. Similar advantages apply over other fastening methods such as for example welding processes. It will therefore be readily appreciated by those skilled in the art that the method disclosed herein is significantly faster than existing methods and provides significant associated cost savings.

[0051] In these and other respects, the invention represents a practical and commercially significant improvement over the prior art. Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms. It should also be understood that the various aspects and embodiments of the invention as described can be implemented either independently, or in conjunction with all viable permutations and combinations of other aspects and embodiments. All such permutations and combinations should be regarded as having been herein disclosed.