AU2004100903A6

AU2004100903A6 - A metal container, and its method of manufacture

Info

Publication number: AU2004100903A6
Application number: AU2004100903A
Authority: AU
Inventors: Mark Trenoweth
Original assignee: GREENWOOD SALES Pty Ltd
Current assignee: GREENWOOD SALES Pty Ltd
Priority date: 2004-10-21
Filing date: 2004-10-21
Publication date: 2004-11-18
Anticipated expiration: 2012-10-21
Also published as: AU2004100903A4

Description

0 O A METAL CONTAINER, AND ITS METHOD OF MANUFACTURE

C,]

O This invention relates a container, and its method of manufacture. In particular, the invention relates to an improved method of making metal toolboxes, and the toolboxes made by that method, although the invention is not limited thereto.

en3 0BACKGROUND ART

O

oConventional heavy duty metal toolboxes are made from several Scomponents which are normally welded together. Such welding is time consuming, 0 S 10 and results in higher manufacturing costs.

It is an object of this invention to provide an improved container, such as a metal toolbox, and a method for making the container, which overcome or ameliorate the abovedescribed problem, or which at least provides a useful choice.

SUMMARY OF THE INVENTION In one broad form, the invention provides a method of forming a container, including the steps of inserting a side insert member between, and coplanar with, spaced flanges on respective opposed sides of the container, placing a backing member so as to extend between the side insert member and each of the spaced flanges, and press joining the side insert member and/or the flanges to the backing member.

In another broad form, the invention provides a container having at least one side thereof formed by a side insert member inserted between, and coplanar with, spaced flanges on respective opposed sides of the container, and a backing member extending between the side insert member and each of the spaced flanges, wherein the side insert member and/or the flanges are press joined to the backing member.

OI

O Typically, both the side insert member and the flanges are press joined to the backing member.

O Alternatively, the backing member may be formed integrally with, or otherwise pre-joined to, either the side insert member or the flanges, and press joined to the other.

n The backing member is normally located on the inside of the container.

0 The backing member may be composed of one or more pieces, and 0 owhere the context permits, the term "backing member" is to be interpreted as Sincluding a plurality of backing members each extending between the side insert 0 S 10 member and a respective flange.

In a preferred embodiment of the invention, the method of forming the container comprises the steps of providing a sheet of predetermined shape, folding edge portions of the sheet to form flanges on opposite sides thereof, folding the sheet into a U shape to form the bottom and a first pair of opposed sides of the container, such that the flanges on each side of the sheet extend in a plane of a respective one of a second pair of opposed sides, placing a side insert member between, and co-planar with, the flanges in each respective plane of the second pair of opposed sides, placing a backing member to span between the insert member and the flanges in each respective plane of the second pair of opposed sides, and press joining the insert member and the flanges in each plane to their associated backing member.

In a preferred embodiment of the invention, the container comprises a sheet of predetermined shape folded into a U shape to form the bottom and a first pair of opposed sides of the container, the sheet having flanges on each side thereof which extend in a plane of a respective one of a second pair of opposed sides, a pair of side insert members, each side insert member being located between, and co-planar with, the flanges on a respective one of the second pair of opposed sides, and 0 O a backing member spanning between each insert member and its associated flanges on each of the second pair of opposed sides, wherein the insert O member and the flanges on each of the second pair of opposed sides are press joined to their associated backing member.

Preferably, the press joining comprises a plurality of TOXTM joints or other clenching method.

0 Typically, the container is a metal toolbox formed from aluminium or

O

O steel sheet components.

In order that the invention may be more fully understood and put into

O

S 10 practice, a preferred embodiment thereof will now be described, by way of example, with reference to the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING Fig 1 is a fragmentary perspective view illustrating the manufacture of a portion of a container according to one embodiment of the invention.

DESCRIPTION OF PREFERRED EMBODIMENT Fig. 1 illustrates a method of forming a container from metal sheet components, such as aluminium "tread plate" or steel sheet, without welding. The container may be used as a toolbox or the like.

A sheet 11 of predetermined shape has its edge portions folded to be perpendicular to the sheet to form flanges 12. (Fig. 1 illustrates only the flanges 12 on one side of the sheet 11, it being understood that the flanges on the other side are substantially identical).

The sheet 11 is then folded into a U shape as shown in Fig. 1, to form the bottom 13 and a pair of opposed sides 14,15 of the container. Before the sheet 11 is folded or bent into the illustrated shape, V-shaped cuts are formed in its upturned edge portions so that mitre joints are formed between the flanges 12 of the bottom 13 and opposed sides 14,15, as shown in Fig. 1. Preferably, the V-shaped cuts are formed in the sides of the sheet before the flanges are formed by folding the edge portions.

The flanges 12 on each side are co-planar.

O A backing member 16 is then placed on the inside of the flanges 12 on each side. The backing member 16 can be a single U-shaped piece of sheet metal, or O individual backing components 16A, 16B, 16C as shown in the embodiment of Fig. 1.

The components 16A, 16B, 16C of the backing member have mitred ends, similar to the mitred portions of the flanges 12.

The backing members 16A, 16B, 16C have a width which is greater

O

0 than the width of the flanges 12, so that they extend into the space between the

O

O flanges.

A side insert member 18 is then placed within the space between the

O

O 10 flanges 12 on each side. The insert member 18 is positioned to be co-planar with the flanges 12, and abuts the backing members 16A, 16B, 16C.

The backing members I16A, 16B, 16C may suitably be provided with two lines of adhesive 17, the outer line of adhesive abutting against a flange 12, and the inner line of adhesive abutting against the insert member 18 to hold the insert member in place in the space between the flanges, at least temporarily until a more permanent connection is made. However, the adhesive is not essential.

As can be seen in Fig. 1, the backing members 16A, 16B, 16C span between the flanges 12 and the insert member 18. The backing members are pressjoined to the flanges 12 and the insert member 18, so that the insert member 18 is permanently fixed in the plane of the flanges 12.

Preferably, the backing members are press-joined to the flanges 12 and insert member 18 by a series of spaced TOX joints 19. A TOX joint is described in US patent 6,722,013, and the subject matter of that patent is incorporated herein by reference.

To form a TOX joint 19 between a flange 12 or insert member 18 and its abutting backing member 16, a punch is placed on one side, and a die is placed on the other side of the abutting sheets. The punch is driven towards the die, to cause deformation of a localised region of the abutting sheets or plates. Namely, the portion of the abutting plates between the punch and the die is deformed into the die to form a button-like connection between the two sheets or plates. Once the punch and die are removed, a small depression remains on the punch side of the joined sheets, and a small button or protrusion is formed on the other side of the joined sheets. Preferably, O the punch is applied to the outside, i.e. to the flanges 12 and the insert member 18, so that there are no buttons or protrusions on the outside of the container.

O A similar procedure is used to form the opposite side (not shown) of the container, The components of the container, i.e. sheet 11, backing members 16A, 16B, 16C and insert member 18 can be made of metal sheet, such as aluminium 0 treadplate. The resultant container can be used as a toolbox or other storage container.

O A container lid or cap, formed from a pressed or roll-formed sheet (not shown) can be Sused as a closure for the open-topped container.

O

S 10 Lip flanges (not shown) can be provided on the top edges of the sides 14,15 and insert members 18.

The method described above, and a container formed using that method, have several advantages, including The components of the container can be joined without welding, thereby resulting in faster and more economical construction.

The construction of the container, i.e. assembly and joining of the components can be automated.

The TOX joints can be formed rapidly.

The resulting container has an aesthetically pleasing appearance, as the side insert members 18 are flush with the flanges 12.

If adhesive is used on the backing members, it will waterproof the joints.

The foregoing describes only one embodiment of the invention, and modifications which are obvious to those skilled in the art may be made thereto without departing from the scope of the invention.

For example, the backing members may be formed integrally with, or otherwise joined to, the insert member 18, and then press-joined to the flanges 12.

Alternatively, the backing members may be formed integrally with, or otherwise joined to, the flanges 12 and press-joined to the insert member 18.

In another embodiment, the backing members are omitted, and a larger side member is used. This larger side member overlies the flanges 12, and is press- 6 0 O joined to the flanges 12, e.g. by TOX joints. However, this embodiment has the

C-]

disadvantage of leaving the edges of the side insert member exposed. To ameliorate O this disadvantage, the larger side insert member 18 may be placed inside the flanges, and press-joined thereto.

n,

O

0

O

0 0 ci

Claims

1. A method of forming a container, including the steps of inserting a side insert member in juxtaposition with spaced flanges on respective opposed sides of the container so that the outer face of the insert member is substantially co-planar with the outer face of the flanges, and press joining the flanges to a backing member extending from the insert member to behind the flanges, wherein the backing member comprises at least one separate portion fixed in use to the insert member, or at least one edge portion integral with the insert member.

2. A method as claimed in claim 1 wherein the container is a toolbox, further including the prior steps of providing a metal sheet of predetermined shape, folding edge portions on opposite sides of the sheet to form said flanges, and folding the sheet into a U shape to form the bottom and a first pair of opposed sides of the toolbox, such that the flanges on each side of the sheet extend in a plane of a respective one of a second pair of opposed sides.

3. A container having at least one side thereof formed by a side insert member in juxtaposition with spaced flanges on respective opposed sides of the container so that the outer face of the insert member is substantially co-planar with the outer face of the flanges, and a backing member extending from the side insert member to behind each of the spaced flanges, the backing member comprising at least one separate portion fixed in use to the insert member, or at least one edge portion integral with the insert member, and wherein the flanges are press joined to the backing member.

4. A metal toolbox comprising a sheet of predetermined shape folded into a U shape to form the bottom and a first pair of opposed sides of the toolbox, the sheet having flanges on each side thereof which extend in a plane of a respective one of a second pair of opposed sides, a pair of side insert members, each side insert member being juxtaposed with the flanges on a respective one of the second pair of opposed sides such that the outer face of the insert member is substantially co-planar with the outer face of the flanges, and a backing member spanning between each insert member and its associated flanges on a respective one of the second pair of opposed sides, the backing member comprising at least one separate portion fixed in use to the respective insert member, or at least one edge portion integral with the respective insert member, wherein the flanges on each of the second pair of opposed sides are press joined to their associated backing member. A method as claimed in claim 1 or 2, or a container as claimed in claim 3, or a toolbox as claimed in claim 4, when the flanges are press joined to the backing member by a plurality of TOX joints.