Title: Top frame assembly
Abstract: A top frame assembly having an upper member having a central opening defined therethrough and a generally planar upper wall, a first plurality of ribs extending downwardly therefrom, and a first mating surface. Also included is a bottom member having a central opening defined therethrough and a generally planar lower wall, a second plurality of ribs extending upwardly therefrom, and a second mating surface, wherein the first and second mating surfaces are attached to each other. Also included is at least one insert member disposed between the upper wall and the lower wall.
Patent Number: 6,983,846 Issued on 01/10/2006 to Koefelda
| Inventors:
|
Koefelda; Gerald R. (Rowlett, TX)
|
| Assignee:
|
Rehrig Pacific Company (Los Angeles, CA)
|
| Appl. No.:
|
705103 |
| Filed:
|
November 10, 2003 |
| Current U.S. Class: |
206/597; 206/527; 428/116 |
| Current Intern'l Class: |
B65D 85/62 (20060101) |
| Field of Search: |
38/1021
108/561,563,572.5,901,902
206/386,453,527,586,597
428/53,116,178
|
References Cited [Referenced By]
U.S. Patent Documents
| 3938448 | Feb., 1976 | Nishitani et al.
| |
| 4229890 | Oct., 1980 | Dropinski.
| |
| 5160029 | Nov., 1992 | Pigott et al.
| |
| 5197396 | Mar., 1993 | Breezer et al.
| |
| 5329862 | Jul., 1994 | Breezer et al.
| |
| 5351629 | Oct., 1994 | Breezer et al.
| |
| 5413052 | May., 1995 | Breezer et al.
| |
| 5492069 | Feb., 1996 | Alexander et al.
| |
| 5596933 | Jan., 1997 | Knight et al.
| |
| 5666886 | Sep., 1997 | Alexander et al.
| |
| 5736221 | Apr., 1998 | Hardigg et al.
| |
| 5791262 | Aug., 1998 | Knight et al.
| |
| 5806436 | Sep., 1998 | Weichenrieder, Sr. et al.
| |
| 5809904 | Sep., 1998 | Darby.
| |
| 5950546 | Sep., 1999 | Brown et al.
| |
| 6006677 | Dec., 1999 | Apps et al.
| |
| 6250234 | Jun., 2001 | Apps.
| |
| 6283044 | Sep., 2001 | Apps.
| |
| 6354230 | Mar., 2002 | Maschio.
| |
| Foreign Patent Documents |
| 3205910 | Nov., 1983 | DE.
| |
| 0 957 039 | Nov., 1999 | EP.
| |
| WO 99/5842/0 | Nov., 1999 | WO.
| |
Other References
Grocery Distribution Magazine, Ad, Jul./Aug. 1999, p. 11.
Chapter 1: Heated Tool Welding, The Handbook of Plastics Joining, Plastics
Design Library, 1997, pp. 1-8.
|
Primary Examiner: Foster; Jim
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 09/576,163 filed
on May 22, 2000 U.S. Pat. No. 6,651,815.
Claims
What is claimed is:
1. A top frame assembly comprising:
an upper member having a central opening defined therethrough, the upper member
having a generally planar upper wall, the central opening extending through the
upper wall, a first plurality of ribs extending downwardly from the upper wall,
and a first mating surface; and
a bottom member having a generally planar lower wall, the central opening extending
through the lower wall, a second plurality of ribs extending upwardly therefrom,
and a second mating surface, wherein the first and second mating surfaces are attached
to each other; and
at least one insert member disposed between the upper wall and the lower wall
for providing strength thereto, the at least one insert member including an upper
surface abutting the upper member and an opposite lower surface abutting the lower member.
2. The top frame assembly of claim 1 wherein the top frame assembly has a generally
rectangular perimeter at least substantially circumscribing the central opening,
wherein the at least one insert member extends along at least one side of the generally
rectangular perimeter.
3. The top frame assembly of claim 1, wherein upper wall and the lower wall have
a generally rectangular perimeter at least substantially circumscribing the central opening.
4. The top frame assembly of claim 1 wherein the at least one insert member is
elongated and is at least substantially parallel to the upper wall and the lower wall.
5. The top frame assembly of claim 4 wherein the at least one insert member is
at least substantially planar.
6. The top frame assembly of claim 1 wherein a width of the upper member between
the central opening and an outer perimeter of the upper member is substantially
less than a width of the central opening.
7. The top frame assembly of claim 1 wherein the upper member and the lower member
include at least one cross member extending across the central opening.
8. The top frame assembly of claim 1 wherein the at least one insert member is
formed separately from the upper member and the lower member and wherein the at
least one insert member is sandwiched between the upper member and the lower member
to retain the at least one insert member in the top frame assembly.
9. The top frame assembly of claim 8 wherein the at least one insert member is
not directly secured to the upper member or lower member.
10. A top frame assembly comprising:
a first member having a first outer surface and a first mating surface spaced
apart from each other by at least one rib, the first outer surface defining a first
central opening extending through the first outer surface, the first member having
a first pair of opposed side members on either side of the first central opening;
a second member having a second outer surface and a second mating surface, the
second mating surface mating with the first mating surface, the second outer surface
defining a second central opening extending through the second outer surface, the
second member has a corresponding second pair of opposed side members on either
side of the second central opening; and
at least one reinforcement member between the first outer surface and the second
outer surface for reinforcing the top frame assembly, wherein the at least one
reinforcement member is a pair of insert members each of which is disposed between
one of the first pair of opposed side members and one of the second pair of opposed
side members.
11. The top frame assembly of claim 10 wherein the at least one reinforcement
member is a metal insert.
12. The top frame assembly of claim 10 wherein the at least one reinforcement
member includes a planar portion.
13. The top frame assembly of claim 10 wherein the top frame assembly is on top
of at least one object on a pallet, the top frame assembly secured to the pallet.
14. The top frame assembly of claim 10 wherein at least one of the first and
second mating surfaces includes a plurality of ribs.
15. The top frame assembly of claim 14 wherein the first and second mating surfaces
are attached to each other such that rib patterns on each of the first and second
mating surfaces defines a plurality of box beam sections extending across a portion
of the top frame assembly.
16. The top frame assembly of claim 10 wherein the first member has a generally
rectangular first perimeter member which includes the first mating surface, and
wherein the second member has a generally rectangular second perimeter member which
corresponds to the first perimeter member, the second perimeter member including
the second mating surface.
17. The top frame assembly of claim 10, wherein the at least one reinforcement
member includes a first planar portion and a second planar portion extending at
a non-zero, non-parallel angle relative to the first planar portion.
18. The top frame assembly of claim 10 wherein the first member and the second
member include at least one cross member extending across the first and second
central openings.
19. The top frame assembly of claim 10 wherein the at least one reinforcement
member includes an upper surface abutting the first member and an opposite lower
surface abutting the second member.
20. A top frame assembly comprising:
a first member having a substantially flat first outer wall and a first mating
surface defined by a first outer flange;
a second member having a substantially flat second outer wall and a second mating
surface defined by a second outer flange for attaching to the first mating surface,
wherein the first and second members each comprise an outer peripheral rail defining
a central opening through the first outer wall and the second outer wall, the first
and second walls spaced apart and oriented substantially parallel to each other; and
at least one insert member disposed between the first and second members for
enhancing the strength of the top frame assembly.
21. The top frame assembly of claim 20 wherein the at least one insert member
is metal.
22. The top frame assembly of claim 21 wherein the first member and the second
member are each molded plastic.
23. The top frame assembly of claim 20 wherein the first member has a generally
rectangular first perimeter member which includes the first mating surface, and
wherein the second member has a generally rectangular second perimeter member which
corresponds to the first perimeter member, the second perimeter member including
the second mating surface.
24. The top frame assembly of claim 20 wherein the first and second members each
comprise an outer, generally rectangular, peripheral rail defining the central opening.
25. The top frame assembly of claim 20 wherein the at least one insert member
includes a plurality of metal inserts.
26. The top frame assembly of claim 20, wherein the at least one insert member
is elongated along a longitudinal axis and includes a first planar portion and
a second planar portion, the second planar portion extending from the first planar
portion in a direction generally perpendicular to the longitudinal axis at a non-zero,
non-parallel angle relative to the first planar portion.
27. The top frame assembly of claim 20 wherein at least one of the first member
and the second member includes at least one cross member extending across the central opening.
28. The top frame assembly of claim 20 wherein the at least one insert member
includes an upper surface abutting the first member and an opposite lower surface
abutting the second member.
29. A top frame assembly comprising:
a first member having a substantially flat first outer wall and a first mating
surface defined by a first outer flange;
a second member having a substantially flat second outer wall and a second mating
surface defined by a second outer flange for attaching to the first mating surface,
wherein the first and second members each comprise an outer peripheral rail defining
a central opening through the top frame assembly, the first and second walls spaced
apart and oriented substantially parallel to each other; and
at least one insert member disposed between the first and second members for
enhancing the strength of the top frame assembly, wherein the top frame assembly
is on top of at least one object on a pallet, the top frame assembly secured to
the pallet.
30. A top frame assembly comprising:
a first member having a substantially flat first outer wall and a first mating
surface defined by a first outer flange;
a second member having a substantially flat second outer wall and a second mating
surface defined by a second outer flange for attaching to the first mating surface,
wherein the first and second members each comprise an outer peripheral rail defining
a central opening through the top frame assembly, the first and second walls spaced
apart and oriented substantially parallel to each other; and
at least one insert member disposed between the first and second members for
enhancing the strength of the top frame assembly, wherein the at least one insert
member includes a first planar portion and a second planar portion extending at
a non-zero, non-parallel angle relative to the first planar portion.
31. The top frame assembly of claim 30 wherein the at least one insert member
has a generally T-shaped cross-section.
32. The top frame assembly of claim 30 wherein the second planar portion extends
generally perpendicularly to the upper wall and the lower wall, the second planar
portion including at least one free edge abutting at least one of the upper wall
and the lower wall.
33. The top frame assembly of claim 30 wherein the second planar portion extends
perpendicularly to the first planar portion.
34. The top frame assembly of claim 30 wherein the at least one insert member
is elongated along a longitudinal axis, at least one of the first planar portion
and the second planar portion having a free edge extending along the longitudinal axis.
Description
TECHNICAL FIELD
The present invention relates to a top frame assembly.
BACKGROUND ART
A top frame is typically used in conjunction with a pallet for the mass shipping
of objects. The top frame is placed on top of a load to stabilize the load for
shipment. The top frame is typically used in conjunction with a pallet which is
positioned at the bottom of the same shipment. Until recently, top frames were
made of wood. However, recent top frames have been molded in plastic. U.S. Pat.
No. 5,160,029 by Pigott et al. discloses a plastic top frame used in association
with palletized goods. The top frame is subject to stress and torsional forces,
and other types of load, such as those forces placed upon the top frame by strap
(S). This top frame use a series of open rib for reinforcement. However, over a
period of extended use, the structure of this top frame may not have sufficient
strength and may tend to deform or fracture under such stress and bending
Accordingly, an improved top frame is desired which is able to withstand
a relatively high amount of load, stress, torsional forces, and bending to which
a top frame is subjected.
DISCLOSURE OF INVENTION
It is an object according to the present invention to provide a top frame which
is able to withstand a relatively high amount of stress and torsional forces.
It is another object according to the present invention to provide a top frame
assembly which has at least one insert member for providing strength and reinforcement
to the top frame assembly.
It is yet another object according to the present invention to provide a top
frame
assembly which receives an insert member for providing strength and reinforcement
to the top frame assembly.
In keeping with the objects and goals according to the present invention, an
improved
top frame assembly is provided which includes a frame portion which defines a receiving
compartment therein, and at least one insert member, but preferably a plurality
of insert members, which is disposed within the compartment of the frame for providing
strength thereto. The insert member is preferably metal. The frame may have generally
rectangular perimeter, wherein the at least one insert member extends along at
least one side of the generally rectangular perimeter. In another embodiment, the
frame may include a pair of planar members having a plurality of rib members extending
therebetween. The frame may also include a top member and a bottom member, where
the top member has an upper surface and a first opposed mating surface, and the
bottom member has a lower surface and a second opposed mating surface, where the
first and second opposed mating surfaces are welded together.
Another embodiment of top frame assembly includes a top member which has
a top surface and a first mating surface, a bottom member which has a bottom surface
and a second mating surface which corresponds to and mates with the first planar
mating surface. Also included is at least one insert member disposed between the
first and second mating surfaces for enhancing the strength of the top frame assembly.
The insert member is preferably a metallic insert and includes a planar portion.
In this embodiment, the top member may have a first pair of opposed side members
including the first mating surface, and the bottom member has a corresponding second
pair of opposed side members which includes the second mating surface, such that
the at least one member is a pair of inserts each of which is disposed between
a respective first and second pair of opposed side members. The top surface and
bottom surface preferably are each planar and oriented parallel to each other,
and the first and second mating surfaces may be defined by corresponding cross-rib
patterns. In such an embodiment, the first and second planar mating surfaces are
attached to each other such that the corresponding cross-rib patterns define a
plurality of whole box beam sections extending across the top frame assembly.
This embodiment may also include a top member which has a generally rectangular
upper perimeter member which includes the first mating surface, and a bottom member
which has a generally rectangular lower perimeter member which corresponds to the
upper perimeter member, and wherein the lower perimeter member includes the second
mating surface.
In still another embodiment according to the present invention, a top frame assembly
is provided which includes a first planar member having a first mating surface,
a second planar member having a second mating surface for attaching to the first
mating surface, wherein one of the first and second mating surfaces is defined
by a rib pattern, which may also include a cross-rib pattern. Also included is
at least one insert disposed between the first planar member and the second planar
member to enhance the strength of the top frame assembly. The insert is preferably
a metallic insert. In this embodiment, the first planar member may include a first
pair of opposed side members which includes the first mating surface, and the second
planar member which has a corresponding second pair of opposed side members including
the second mating surface, such that the insert is a pair of inserts each of which
is disposed between a respective first and second pair of opposed side members.
Further, in this embodiment, the first planar member may have a first outer
surface and the second planar member has a second outer surface, such that the
first and second outer surfaces are oriented parallel to each other. The first
and second planar mating surfaces are attached to each other such that the rib
pattern define a plurality of whole box beam sections extending across the top
frame assembly. The top member may have a generally rectangular upper perimeter
member which includes the first mating surface, and the bottom member may have
a generally rectangular lower perimeter member which corresponds to the upper perimeter
member, so that the lower perimeter member includes the second mating surface.
In still another embodiment according to the present invention, provided is a
top frame assembly which has a pair of opposed side members and also includes a
top member having a top pair of opposed side portions, a bottom member which is
mounted to the top member and has a bottom pair of opposed side portions corresponding
to the top pair of opposed side portions, such that the top and bottom pairs of
opposed side portions mate with each other to define the pair of opposed side members.
Also included is a plurality of insert members disposed between top and bottom
pairs of opposed side portions for enhancing the strength of the top frame assembly.
The inserts are preferably metallic and planar. The top member includes a top surface
and the bottom member includes a bottom surface, such that the top and bottom surfaces
are each planar and oriented parallel to each other. The top pair of opposed side
portions include a first mating surface, and the bottom pair of opposed side portions
include a second mating surface, such that at least one of the first and second
mating surface is defined by a rib pattern, which may be a cross-rib pattern.
The first and second mating surfaces are attached to each other such that the
mating surfaces define a plurality of whole box beam sections extending across
the top frame assembly. In this embodiment, the top member may have a generally
rectangular top perimeter member which includes the top pair of opposed side portions,
and the bottom member may have a corresponding generally rectangular bottom perimeter
member which includes the bottom pair of opposed side portions, and such that the
top perimeter member includes a first mating surface and the bottom perimeter member
includes a second mating surface for attaching to the first mating surface.
Provided according to the present invention is another top frame assembly
which includes a first member having a planar first mating surface, a second member
which has a planar second mating surface attached to the first mating surface,
and at least one insert member having a planar portion and is disposed between
the first and second members and oriented generally parallel to the first and second
mating surfaces. Preferably, the insert is a metallic insert. The first member
may have a first pair of opposed side members including the first mating surface,
and the bottom member may have a corresponding second pair of opposed side members
which includes the second mating surface, such that the at least one planar insert
is a pair of inserts each of which is disposed between a respective first and second
pair of opposed side members. The first member includes a first outer surface and
the second member includes a second outer surface, such that the first and second
outer surfaces are each planar and oriented parallel to each other. Also, at least
one of the first and second mating surfaces may be defined by a rib pattern, and
may include a cross-ribbing pattern. Still further, the first and second mating
surfaces are attached to each other such that the mating surfaces define a plurality
of whole box beam sections extending across the top frame assembly. Still further,
the first member has a generally rectangular first perimeter member which includes
the first mating surface, and the second member has a generally rectangular second
perimeter member which corresponds to the first perimeter member, and where the
second perimeter member including the second mating surface.
Also provided in accordance with the present invention is a top frame assembly
having an upper frame portion having a generally rectangular upper perimeter member
with a first mating surface, a lower frame portion having generally rectangular
lower perimeter member corresponding to the upper perimeter member, the lower perimeter
member having a second mating surface attached to the first mating surface. Also
included is a plurality of planar insert members disposed between the first and
second mating surfaces for enhancing the strength of the top frame assembly. The
upper perimeter member has a first pair of opposed side members including the first
mating surface, and the lower perimeter member has a corresponding second pair
of opposed side members including the second mating surface, such that each of
the plurality of inserts is disposed between a respective first and second pair
of opposed side members. The upper perimeter member may also include a first outer
surface, and the lower perimeter member may include a second outer surface, such
that the first and second outer surfaces are each planar and oriented parallel
to each other. One of the first and second mating surfaces may be defined by a
rib pattern. The first and second mating surfaces are attached to each other such
that the rib pattern defines a plurality of whole box beam sections extending across
the top frame assembly.
The above objects and other objects, features, and advantages of the present
invention are readily apparent from the following detailed description of the best
modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of the top frame assembly according to the present invention;
FIG. 2 is a top plan view of the top frame of FIGS. 1-3, the bottom plan view
being a mirror image thereof;
FIG. 3
a is an exploded perspective assembly view of the top frame assembly
according to the present invention and particularly illustrates an insert between
the upper and lower top frame members according to the present invention;
FIG. 3
b is a perspective view of one top frame portion according to the
present invention having a plurality of inserts disposed thereon; and
FIG. 4
a is an exploded, enlarged, partial perspective view of the bottom
member of the top frame shown in FIG. 4
a having the first embodiment of
the insert separated therefrom;
FIG. 4
b is an enlarged, partial perspective view of the bottom member
of the top frame assembly having the first embodiment of the insert positioned thereon;
FIG. 5
a is a partial cross-sectional view of the top frame assembly taken
along line A—A of FIG. 3
b, illustrating the first embodiment of the
insert member shown in FIGS. 3
a-3
b;
FIG. 5
b is a full cross-sectional view of the top frame assembly shown
in FIG. 5
a, taken along the line B—B of FIG. 2;
FIG. 6
a is a partial cross-sectional view of the top frame assembly similar
to that of FIG. 5, illustrating a second embodiment of the insert member;
FIG. 6
b is a full cross-sectional view of the top frame assembly similar
to that of FIG. 6
a with the second embodiment;
FIG. 7
a is a partial cross-sectional view of the top frame assembly similar
to that of FIG. 5, illustrating a third embodiment of the insert member;
FIG. 7
b is a full cross-sectional view of the top frame assembly similar
to that of FIG. 7
a with the third embodiment;
FIG. 8
a is a cross-sectional view of the top frame assembly similar to
that of FIG. 5, illustrating a fourth embodiment of the insert member;
FIG. 8
b is a full cross-sectional view of the top frame assembly similar
to that of FIG. 8
a with the fourth embodiment;
FIG. 9 is a partial cross-sectional perspective view of the bottom member of
the top frame assembly showing adjacent side and end members, each having an insert
member disposed thereon;
FIG. 10 is another partial cross-sectional perspective view of the bottom member
of the top frame assembly showing adjacent side and end members similar to FIG.
9, the end members having a vertically oriented insert and the side members having
a horizontally oriented insert;
FIG. 11 illustrates a partial cross-sectional view of the top frame assembly
taken along line C—C of FIG. 3
b through the hole of the insert member,
illustrating the first embodiment of the insert member shown in FIGS. 3
a-3
b;
FIG. 12 is a perspective cross-sectional view of a side of the top frame assembly
which does not include an insert member disposed between the upper and lower top
frame members, taken along line D—D of FIG. 2;
FIGS. 13
a-f illustrate the method according to the present invention
of forming and assembling the top frame assembly;
FIG. 14 is a side elevational view of a top frame assembly in use in conjunction
with a pallet, and having layers of objects with slip sheets disposed therebetween;
FIG. 15
a is a perspective view of another embodiment of the top frame
assembly according to the present invention;
FIG. 15
b is a cross-sectional view taken along line E—E of FIG.
15
a;
FIG. 16
a is a perspective view of still another embodiment of the top
frame assembly according to the present invention;
FIG. 16
b is a cross-sectional view taken along line F—F of FIG.
16
a;
FIG. 17
a is a perspective view of yet another embodiment of the top frame
assembly according to the present invention;
FIG. 17
b is a cross-sectional view taken along line G—G of FIG.
17
a;
FIG. 18
a is a perspective view of another embodiment of the top frame
assembly according to the present invention having a cross-member therein; and
FIG. 18
b is a cross-sectional view taken along line H—H of FIG.
18
a.
BEST MODE FOR CARRYING OUT THE INVENTION
Disclosed herein is a top frame assembly
10 according to the present
invention, illustrated in FIGS. 1-3. FIG. 1 illustrates a perspective view of top
frame assembly
10. Top frame
10 is preferably formed of a thermoplastic
or other polymeric material and is also preferably, but not necessarily, formed
by an injection molding process. Top frame
10 is shown in FIGS. 1-3 as having
a generally rectangular shape and also as being generally symmetrical about each
centerline. However, it is fully contemplated that top frame assembly
10
may have various shapes and configurations without departing from the teachings
according to the present invention. For example, top frame assembly
10 may
also include one or more members or cross-members extending across central opening
26 (as illustrated in FIG. 18
a.) FIG. 2 illustrates a top plan view
of top frame assembly
10.
As best illustrated in the exploded perspective view of FIG. 3
a, top frame
assembly
10 includes an upper (first, top) member
12 and a lower
(second, bottom) member
14 which correspond to and mate with each other.
Particularly, as illustrated in FIGS. 2,
3a and
5b,
upper member
12 has a flat, planar upper surface
16, and also includes
a lower (first mating) surface
18. Lower member
14, on the other
hand, includes a planar lower surface
20 and also includes an upper (second
mating) surface
22. With further reference to FIG. 5
b, mating lower
surface
18 of upper member
12 mates with and attaches to corresponding
upper surface
22 of bottom member
14. More particularly, planar mating
surface
18 of upper member
12 is generally defined by outer edge
19 which is a downwardly projecting flange member which extends around the
perimeter of upper member
12, and also by inner edge
21 which is
also a downwardly projecting flange member which extends around the interior of
upper member
12 and helps define opening
26. As shown in FIGS. 5
b,
6b,
7b,
8b, upper member
12 may
also include ribs
24 which generally correspond to and mirror those ribs
25 of bottom member
14 shown in FIGS. 3
a and
3b
and which are also generally co-planar with outer and inner edges
19,
21.
With regard to lower member
14, planar mating surface
22 of lower
member
14 is generally defined by outer edge
29, which is an upwardly
projecting flange member
29 (which extends around the perimeter of lower
member
14 and corresponds to upper mating flange
19), and is also
defined by inner edge
31 which extends around the interior of lower member
14 and corresponds to mating flange
21. Those ribs
27 disposed
below insert members
80 are generally not co-planar with edges
29,
31,
as shown in FIGS. 5
a,
6a,
7a,
8a.
However, ribs
25 in corner portions
35 which do not have an insert
member according to the present invention may be fully co-planar with edges
29,
31.
Ribs
25 and
27 may of course include cross-ribbing as shown in FIGS.
3
a-
3b. Also, it is fully contemplated that one of upper member
12 and bottom member
14 may have a ribbing pattern, including cross-ribbing,
while the other may include a mating surface
18,
22 which is planar
sheet of plastic without ribs which is welded or attached to the opposed mating surface.
With reference to FIG. 1, in the embodiment illustrated, top frame assembly
10 has a central opening
26 defined by an outer rail
28, which
includes a first pair of opposed side members
30,
32 and a second
pair of opposed side members
34,
36. For ease of reference, the first
pair of side members may be referred to as side members
30,
32, while
the second pair of opposed side members may be referred to as end members
34,
36.
Referring again to FIGS. 3
a and
3b, side member
30
is defined by upper side member
38 and lower side member
40. Side
member
32 is defined by upper side member
42 and lower side member
44. End member
34 is defined by upper end member
46 and lower
end member
48. End member
36 is defined by upper end member
50
and lower end member
52.
Further, with reference to FIG. 1, side members
30,
32 respectively
include a first pair of opposed outer edges
54,
56 (side edges), while
end members
34,
36 respectively include a second pair of opposed outer
edges
58,
60 (end edges). Referring again to FIGS. 2,
3a
and
3b, edge
54 is defined by upper member and lower member
edges
62,
64, respectively. Edge
56 is defined by upper member
and lower member edges
66,
68, respectively. Edge
58 is defined
by upper member and lower member edges
70,
72, respectively. Edge
60 is defined by upper member and lower member edges
74,
76,
respectively. Upon welding or fastening members
12,
14 together according
to the present invention, a parting line
78 results between the respective
mating edges. (See FIG. 1.) Outer edge
19 of upper member
12 includes
edge portions
62,
66,
70, and
74, while outer edge
portion
29 of lower member
14 includes edge portions
64,
68,
72, and
76.
As illustrated in FIGS. 3
a,
3b,
4a,
4b,
5a, and
5b and in accordance with the present invention,
top frame assembly
10 also includes at least one, but preferably a plurality,
of insert members
80 which provide and enhance the strength, reinforcement,
and stiffness properties of top frame assembly
10 (see also the other embodiments
of the insert member illustrated in FIGS. 6
a,
6b,
7a,
7b,
8a, and
8b.) As illustrated in FIGS.
3
a-
3b, a pair of elongated, longitudinally extending insert
members
80 are shown disposed in a generally planar orientation between
upper member
12 and bottom member
14 such that it is sandwiched between
both mating surfaces
18,
22 and generally parallel thereto. For example,
as illustrated in FIGS. 3
a-
3b, insert member
80 is
positioned between each corresponding pair of rail upper and lower side members
38,
40 and
42,
44.
Insert member
80 is preferably formed of metal, but may be also formed
of composite or structural plastic, or any other material providing the desired
properties. In one embodiment of a rectangular top frame assembly
10 which
is
56 inches long, 44 inches wide and 1.5 inches deep, insert
80
centrally disposed within side members
30,
32 and is 52 inches long,
3.5 inches wide, and 0.025 inches thick. With reference to FIGS. 3
a and
3b, insert
80 is illustrated as extending along the length
of each of the side members
32,
34 (and positioned between slide members
38,
40 and
42,
44) whereas no insert is shown along the
end members
34,
36 (or between end members
46,
48 and
50,
52.) Also, while no portion of insert member is shown extending
into the corner areas
35, in other embodiments it may extend across top
frame assembly
10 and into the corner areas. Prior to attaching upper member
12 and lower member
14, insert member
80 extends widthwise
between outer edge
29 and inner edge
31 of lower frame member
14.
Thus, after insert member
80 or plurality of insert members
80
are positioned on the desired side rails of either the upper or lower member (
12
or
14), the members
12,
14 are heated and introduced to each
other as described herein in association with FIGS. 13
a-
13f.
Note that insert members
80 are illustrated as being generally solid and
continuous, except for a plurality of holes
82 and notches
84 formed
therein. Because of the generally solid and continuous nature of insert members
80, the majority of the inner rib pattern or structure of those portions
of rail
28 which are covered by insert
20 are therefore not able
to mate with the corresponding rib structure. For example, in FIGS. 3
a and
4a, the ribs along lower side members
40,
44 (such
as plurality pattern of ribs
79 and
81) are covered by insert member
80 and thus they will not mate with or weld with the corresponding mating
ribs
24 of upper side members
38,
42, respectively (see also
FIGS. 5
b,
6b,
7b, and
8b.) In
those areas, the welding takes place along side members
30,
32, by
way of welding together upper and lower outer edges
19,
21, and also
the co-planar upper and lower inner edges
29,
3. In areas having insert
member
80 disposed therebetween, the welding or attachment may also take
place through portions of ribs
25 which are exposed through holes
82
and notches
84 in insert member
80, and thus are able to mate and
be welded together in these areas for greater surface area attachment between upper
and lower members
12,
14 (best shown in the cross-sectional view of
FIG. 10 taken through hole
82 in insert
80, and also shown in FIG. 4
b.)
FIG. 5
a is an enlarged, partial cross-sectional view of the bottom member
of the top frame assembly having the first embodiment of planar, flat insert member
80 positioned thereon, taken along line A—A of FIG. 3
b. FIG.
5
b is a cross-sectional view of the top frame assembly taken along line
B—B of FIG. 2, illustrating the first embodiment of the insert member shown
in FIGS. 3
a,
3b,
4a, and
4b.
FIGS. 6
a,
6b,
7a,
7b,
8a
and
8b and
8-
10 illustrate other various possible
designs and embodiments of the. insert member according to the present invention.
Of course, the various insert member embodiments are illustrated by way of example
and not limitation, as the insert member disclosed herein may have any number of
designs and configurations, the selection of which may be chosen based on the desired
use, application, and properties of the top frame assembly.
FIG. 6
a is a partial cross-sectional view of the top frame assembly similar
to that of FIG. 5
a, illustrating a second embodiment of the insert member
90 positioned upon side member
30 of rail
28. As illustrated
in FIGS. 6
a-
6b, insert member
90 is shaped like a "T",
having a flat planar portion
92 and a second planar portion
94 oriented
perpendicular thereto, thus having portions
96,
98 extending into
upper member
12 and lower member
14, adjacent inner walls
21,
31. FIG. 6
b is a view similar to that of FIG. 5
b.
FIG. 7
a is a cross-sectional view of the top frame assembly similar to
that of FIG. 5, illustrating a third embodiment of the insert member
100.
FIG. 7
b is a cross-sectional view of the top frame assembly similar to that
of FIG. 5
b, illustrating insert member
100. As illustrated in FIGS.
7
a-
7b, from outer wall
21, insert member
100
extends inwardly and has a flat planar portion
102 which transitions into
an angled portion
104 extending into upper member
12, and then has
an end portion
106 which extends downwardly at 90° within lower member
14, proximate inner wall
31.
FIG. 8
a-
8b are other partial cross-sectional views of top
frame assembly
10 similar to that of FIGS. 5
a and
5b,
illustrating a fourth embodiment of the insert member
110. As shown therein,
has a flat planar portion
112, and an end portion
114 extending perpendicular
thereto toward one of the upper member
12 and lower member
14, and
particularly shown oriented in a downward orientation.
In another embodiment according to the present invention, insert members according
to the present invention are located on each of the side and end members
40,
44,
48, and
52 of bottom member
14 of top frame assembly
10, as shown in the partial cross-sectional view in FIG. 9 of the symmetrical
top frame assembly. As illustrated therein, an insert member
80 is disposed
on each of the side members
40,
44 and end members
48,
52
for providing strength and resistance against deformation and buckling along each side.
In yet another embodiment shown in FIG. 10, side member
40 of bottom top
frame member
14 includes an insert member
80 extending thereacross,
as previously shown and described in association with FIGS. 3
a and
3b.
Moreover, end member
48 includes a vertically oriented insert member
120
(which, with reference to FIGS. 6
a-
6b, is similar to the vertically
oriented portions
96,
98 of insert member
90, but does not
have flat planar portion
92.) In a rectangular top frame, the longer side
members
30,
32 may tend to deflect inward horizontally, or in a plane
parallel to the insert member
80 or top surface
16. Therefore, planar
insert members
80, or those substantially planar such as insert members
90,
100,
110, may be used to provide strength and reinforcement
in this direction. On the other hand, the shorter end members
34,
36
may tend to bow or buckle under load (strapping forces), causing deflection in
the vertical direction, or away from horizontal. Thus vertically oriented insert
member
120 may be used to provide strength and reinforcement in those directions.
In the embodiment of a top frame assembly
10 which is 56 inches long, 44
inches wide and 1.5 inches deep, insert member
120 may be 1.0 inch tall,
0.025 inch thick, and 40 inches long.
As shown in FIGS. 6
a-b,
7a-b, and
10, a portion of
vertical insert members
90,
100, and
120 may extend above
planar surface
22. Thus, if a hot plate welding process is used to assemble
this top frame assembly as illustrated in FIGS. 13
a-f, a groove maybe formed
within the platen
326 to accommodate such upwardly extending portions of
the various insert members.
Of course, it is fully contemplated that the insert members are not limited to
those designs shown, but may have any shape or design in furtherance of the teachings
according to the present invention. Also, any of the insert members disclosed and
shown herein according to the present invention may be used in any area of top
frame assembly
10 to provide the desired reinforcement, and are not limited
to placement in those areas or top frame members disclosed. For example, any of
the insert members may be used as desired to reinforce one or more of side and
end members
30,
32,
34, and
36. In addition, should top
frame assembly have members or cross-members extending across opening
26,
those members may also include insert members for reinforcement according to the
present invention, as illustrated in FIGS. 18
a-b. Further as illustrated
in FIGS. 15-17, the teachings according to the present invention are not limited
to two piece top frames which have an insert and are welded together, but may include
any top frame having a reinforcing insert as disclosed and taught herein.
With reference to the cross-sectional views of FIGS. 5
a,
6a,
7a, and
8a, it is noted that the ribs
27,
81,
79 upon which the insert members rest have a lower height than the adjacent
portions of outer and inner edges
29,
31, respectively (i.e. below
surface plane
22). This allows the insert members
80 to be securely
positioned within lower member
14 below planar surface
22, prior
to the welding process discussed below. As illustrated in FIGS. 5
b,
6b,
7b and
8b, this allows the portions of edges
29,
31
and ribs
25 to be plasticized during the welding process as disclosed further
herein. In the other embodiments of insert members
90,
100, and
110,
the lower profile rib portions
27 disposed below the insert members allow
the relatively large flat, planar portion (
92,
102, and
112)
of these insert members to be securely positioned therein. As shown in FIGS. 5
b,
6b,
7b and
8b, after welding, the insert
is preferably co-planar with the parting line
78, but of course may vary
due to welding and build variations.
According to the present invention, top frame members
12,
14
are preferably fastened to each other by a hot plate welding operation, known in
the art. (See FIGS. 13
a-
13f.) In these portions without inserts,
the corresponding ribs on both members
12,
14 are aligned so they
preferably are welded together by plasticizing their mating surfaces to form box-beam
sections, resulting in a top frame assembly where every section without an insert
has a box beam. Note that the order of the plasticizing procedure is provided for
illustrative purposes only, and of course, such steps may be performed in any feasible
order. Also the plasticizing process for the top frame may also be accomplished
by infrared radiation or another process designed to provide the desired properties
of top frame
10.
Attention is directed to the method of assembling top frame assembly
10
according to the present invention. The preferred manufacturing assembly process
is by the hot plate welding process which is best illustrated in FIGS. 13
a-
13f
of the drawings. As indicated above, however, any suitable fastening means
may be used such as, for example, infrared radiation, epoxy, etc. The hot plate
welding process may be characterized as either contact hot plate welding or non-contact
hot plate welding. This process should provide weld strength properties and produce
seals between the mating (welded) components as strong as those of the parent polymer.
According to the present invention, the top frame mating surfaces, are either placed
in contact (in the contact hot plate welding process) or closely approach (in the
non-contact variation) a heated platen
156 (preferably formed of steel)
or similar tool in order to create a molten or plasticized region on the mating
surfaces. Platen
156 is then moved out of the way and the plasticized regions
are then pressed together to form the weld.
As illustrated in FIG. 13
a, more particularly, in practice, the process
is operated on a hot plate welding machine
150 (known in the art) in which
the corresponding top frame
12,
14 members which are to be welded
together are securely attached by clamping in holding fixtures
152 and
154.
With reference to FIG. 13
b, platen
156 of welding machine
150
is heated to a predetermined temperature and is extended between the separated
upper member
12 and bottom member
14. Holding fixtures
152
and
154 are moved toward each other and toward platen
156, whereupon
the weld planes of top frame members
12,
14 are either pressed against
platen
156 (by the contact version using conducted heat) or are moved closely
to platen
156 (by the non-contact version using radiant heat.) The choice
of which method to use is dependant on many factors including the properties of
the materials to be welded; cycle times required; size and design of the component;
accuracy and repeatability of the welding machine; and use of the welded component.
In the contact hot plate welding process, heat is conducted by way of physical
contact of members
12,
14 to be welded with heated platen
156
(FIG. 13
c). Further, the surface of each mating surface
18,
22
is plasticized or melted until contact is complete (referred to in the art as "matching").
At this point, further platen
156 movement is often halted, and heating
is continued, in order to create a deeper (to a predetermined depth), and relatively
more molten, plasticized zone in which material is displaced. In the non-contact
process, FIG. 13
c is disregarded and surfaces
18,
22 do not
contact platen
156, but instead radiant heat is applied to the parts to
be welded which is generated by holding the parts to be welded very close to the
heated platen (target plates) and allowing them to heat over time.
With reference to FIG. 13
d, for either version, after a predetermined
period of time, heating is complete and the surface melting has reached a predetermined
melt depth, the parts are retracted from platen
156. Platen
156 is
then moved out of the way, whereupon the adjoining top frame members
12,
14
are forged together and held for a predetermined period of time until the plasticized
material is stabilized and the mating surfaces cools. (See FIG. 13
e.) Mechanical
or microprocessor-controlled stops may be used to control the amount of material
displacement of the top frame polymer from the weld zone, particularly during the
heating phase. Finally, with reference to FIG. 13
f, fixtures
152
and
154 are separated to their part loading position and welded top frame
assembly
10 with insert contained therein, is held to one of the fixtures
(shown in FIG. 13
f as fixture
154) for unloading. The part is then
removed from welding machine
150.
Weld times to form top frame assembly
10 may vary with the volume of
polymer to be fused and the thermal conductivity of the respective top frame member.
Accordingly, welding times for top frame assembly
10 may fall in the range
from 5 to 60 seconds, although the mass of top frame members to be plasticized,
the size and quantity of the insert members, and the corresponding cooling rates
will govern cycle times. The size of top frame assembly
10 that may be hot
plate welded according to the present invention is limited only by the practical
size of holding fixtures
152 and
154 and platen
156 of welding
machine
150, and also of the mechanics of the removal of the welded assembly
or subassembly from the weld zone and moving top frame assembly
10 components
for forging them together.
Each of the contact and non-contact methods have their advantages, including:
in the non-contact method, no special coating on platen
156 is required
for material release, no residue builds-up on platen
156, there is no loss
of weld edge material against heated platen
156 and finished parts have
consistent weld characteristics. Whereas, the advantages of contact heating are
a quicker cycle time, lower temperature required for platen
156, the method
is more tolerant of larger design components, such as top frame assembly
10
disclosed herein, and also more tolerant of less dimensionally consistent components.
Welding top frame assembly
10 as described herein with insert
80
provides a high strength weld suitable for parts operating under pressure. The
parting line
78 is relatively inconspicuous. Further, no other attachment
methods, such as adhesives, solvents, mechanical fasteners such as nails or staples,
are required. Also, complex shapes are capable of being welded since there is no
relative motion required in the welding process.
Another assembly process known as infrared radiation may also be used as
a non-contact alternative to hot plate welding for use in forming and assembling
top frame assembly
10 according to the present invention. In such a process,
the infrared radiation is often supplied by high intensity, quartz heat lamps which
produce radiation having wavelengths of around one micron. As with hot plate welding,
when this radiation is applied to mating surfaces
18,
22 of top frame
assembly
10, plasticization of the surfaces occurs. In one application,
radiation source, such as heat lamps, are removed after melting has occurred and
the parts are forged together just as with the platen in hot plate welding. Infrared
welding tends to melt the zone relatively quickly. Hot plate welding uses conduction
to create the necessary plasticized zone. Of course, as with any other process,
the depth of penetration of the plasticization depends on many factors and it varies
strongly with only minor changes in polymer formulation.
As noted above, ribs
27,
79,
81 disposed below the corresponding
insert members have a lower profile creating a pocket into which the insert member
may be positioned prior to the above welding processes. However, it is also contemplated
that ribs
27,
79,
81 upon which insert
80 rests, may
be co-planar with edges
29,
31 to assist in defining planar surface
22. In this design, when the respective ribs
24,
27 above and
below the insert members
80 are plasticized, the upper and lower members
12,
14 are held together for bonding, and the insert member displaces
the plasticized material in those regions, thereby fitting between upper and lower
members
12,
14, and also allowing for additional bonding between the
plasticized top frame plastic and the metal insert member.
FIG. 14 shows a top frame
