GB2284802A - Construction assembly - Google Patents

Abstract

An assembly 1 is constructed from a series of components 10, 10', 10" and 10'" component which may be nested together in a first configuration in which some or all of them are stacked one on top of the other or arranged in a second configuration in which they lie substantially flush. The components may thus be stored in the second configuration so as to make effective use of storage space. The assembly may form a box, bowl, tray, hat, plant pot, stand or boat hull. <IMAGE>

Description

CONSTRUCTION ASSEMBLY This invention relates to an assembly of components for construction and various uses for the constructed assembly.

The provision of storage facilities for components and assembled products is a significant cost to industry.

A reduction in the amount of space required for storage of such products would be advantageous in terms of savings in cost or in releasing space for other uses.

The same considerations apply to the end use of the products. Provision of a means for reducing storage space required for a product would be advantageous and may encourage sales of the product.

There are many products which, when assembled, occupy a substantially greater volume of space than the aggregate space occupied by their components parts prior to assembly. In this regard potential storage space may be wasted.

The present invention seeks to alleviate such problems by providing a means for reducing wastage of storage space for an assembled product and/or its components.

With this in mind, according to a broad aspect the present invention provides an assembly of nestable components, the nested assembly having a first configuration in which a series of the nested components are stacked and a second configuration in which the series of nested components lie substantially flush. In this respect the first configuration may conveniently be achieved by arranging the components in a first orientation and the second configuration may be achieved by inverting at least some of the components to a second orientation.

Thus, the present invention may ease storage and handling of assembled products by providing components which may be stored in a relatively flat format, (i.e.

the second configuration of the assembly) thus making considerable savings in terms of storage space. However, the same components may be stacked to provide an assembled product which can occupy significantly greater space than its components, i.e. the first configuration of the assembly.

In another aspect the invention provides components for such an assembly. Further aspects of the invention include a method of making an article which includes providing components as aforesaid.

It will be appreciated that an assembly, when in its first configuration, may have a whole host of applications. Some or all of the components may be stacked together in an order of increasing size in either orientation, for example. In this way, if each component is a substantially closed loop of any shape, together the components may define a well. This may be used for storage purposes. For example, such an assembly could be employed for a variety of household purposes, such as a display/gift box, a bowl, or tray, or container for storage, as a hat or as a plant pot for example. In addition, the assembly may have applications in the building trade, as a boat hull or garden pond template.

In the alternative, the assembly may be constructed so that some or all of the components are stacked in an order of decreasing size. Again, an assembly in such a first configuration may be put to a wide variety of uses.

For example, stands or podiums may be constructed in this way. This could include small scale stands (such as for cakes) or larger scale stands, such as used in shop window dressing.

The stacked components may also be used in place of various mouldings, such as applied to walls or ceilings, window and cupboard tops or doors or fireplaces, for example. Similarly, the assembly could provide picture frames.

As a combination of the previous example assemblies, sets of stacked components may be brought together to provide a closable container, such as required for a spinning top or other toy, or for Christmas baubles.

An assembly in a first configuration may also be used.for educational purposes such as a three-dimensional map, for example. Thus, the components may be configured to define contour lines for the map. In the alternative, the assembly may be used for toys and games. For example, when in a first configuration, the assembly may provide a three-dimensional play surface, as an alternative to the two-dimensional surfaces currently used in board games and which may also be provided by the present assembly (when in the second configuration).

In preferred embodiments the assembly includes a first component having formations for supporting a second component stacked thereon to provide the first configuration of the assembly, the second component having inverse formations arranged so that the respective formations on the first and second components are capable of mating together when the second component is inverted so that the components lie flush to provide the second configuration of the assembly.

Suitably, the assembly includes at least some components which have opposing first and second surfaces and two opposing side faces adjoining said surfaces, wherein the side faces of the components have formations for interengagement with formations on other components.

Conveniently the formations are arranged so that a side face of a first component provides a support means for a second component when the assembly is in a first configuration. Thus, in use, a side face of a first component will abut a side face of a second component.

Preferably, the side faces of a component are curved or angled, rather than being flat in shape. In this way surface formations in a side face of a first component may accommodate formations in a side face of another component. Preferably each side face of a component is configured to define a receiver part and an engager part.

Suitably a receiver part is arranged at or near the first or second surface and an engager part arranged at or near the other surface. Suitable example receiver parts include curved recesses or channels and example engager parts comprise ridges or projections or similar. The dimensions of the components will be selected so that a receiver of one component may accommodate an engager of a second component. For example a recess in a first component may receive a projection in a second component.

In preferred embodiments in a cross-section, preferably any cross-section, of a component the first and second surfaces are of different extents in terms of lengths or widths. In this regard, preferably a component has two curved side faces so that, in crosssection, a component is in the form of a neck and shoulders to provide the engager and receiver parts.

Preferably respective components are incrementally larger/smaller so that, in use, a shoulder of a first component may support a shoulder of a second component.

For some embodiments it is preferable but not essential that the components are of substantially constant crosssection throughout.

In particularly preferred embodiments both the first and second surfaces of the components are substantially flat. This is advantageous because the first and/or second surfaces of the components may together define a generally flush surface when the components are in the second configuration. Preferably the first and second surfaces have curved or angled boundaries so that they are generally non-linear in outline. In some preferred embodiments the surfaces are of generally arcuate form.

In some particularly preferred embodiments the first and second surfaces are substantially annular. In this respect at least some of the components may be of generally circular shape, or of regular polygonal shape, or of a host of other more complex shapes. In most preferred embodiments the first and second surfaces are concentric circular rings, of different respective radii so that a component is of generally frustoconical shape.

Use of generally frustoconical components may be advantageous in that it can permit relative rotation of components in the assembly, if desired. Preferably any such concentric rings whether circular or otherwise include flat first and second surfaces joined by edge faces each having a receiver part adjacent the first surface and an engager part adjacent the second surface.

Most preferably, for at least some of the components in cross-section a component is generally symmetrical.

Preferably, the components are of a form which permits the assembly to adopt a first configuration in which at least some of the components are stacked when the components are arranged in a first orientation and when at least one of the said components are inverted to adopt a second orientation.

It will be appreciated that any number of components may be included in the assembly, depending upon the desired form or size of the assembly when in its first configuration. Also, one or more sets of components of differing sizes and shapes may be nested within a larger set of components. In addition, the depth of each component (that is the spacing between the first and second surfaces) may be selected according to the desired height of the completed stack. Preferably the assembly includes a series of components all of the same depth and with flat first and second surfaces so that, in the second configuration, opposing surfaces of the assembly are generally flush.

Furthermore, accessories may be provided for combining such assemblies. In preferred embodiments such an accessory may have opposing surfaces, each capable of receiving or generally mating with a component in an assembly. Suitably such accessories are machined on both surfaces so that each is a mirror image of the other through the centre of the accessory. Alternatively or in addition, in some embodiments an accessory may be provided with formations capable of interengagement with formations on a component so as to support the component in a desired orientation.

Specific embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which: Fig. 1 shows in cross section an example assembly in a first configuration; Fig. 2 shows in cross section an example assembly in a second configuration; Fig. 3 shows a plan view of a second example assembly in a second configuration; Fig. 4 shows a perspective view of the assembly of Fig. 3 in a first configuration; Fig. 5 shows a plan view of two series of components for the second embodiment, with a first series on the left and a second series on the right; Fig. 6 shows a cross section of a cutting head for manufacture of components; Fig. 7 illustrates workpieces for manufacture of components; and Figs. 8A to 8D show other example cutting heads in cross-section.

Turning firstly to Fig. 1, this illustrates an assembly 1 of components 10, 10' etc. The assembly 1 is arranged in a first configuration with components 10, 10' nested and stacked. In more detail, a first component 10 has a first flat surface 11 and an opposing flat second surface 12. Both surfaces 11, 12 are annular having internal and external generally circular boundaries, with surface 12 being wider than surface 11, so that the component 10 is generally of frustoconical shape. All the components 10, 10' are of substantially the same depth.

The first component 10 also has opposing curved side faces 15, 16. Side face 15 lies between the two external boundaries of surfaces 11 and 12, and side face 16 lies between the internal boundaries of these surfaces. Each face 15, 16 defines a receiver part 25,26 and an engager part 35, 36 respectively. In cross-section the component 10 is generally symmetrical about axis A. The component 10 is also of constant cross-section throughout. In the illustrated component 10 side face 15 faces outwardly with respect to the assembly 1 and side face 16 faces inwardly.

A second component 10' also has opposing flat first and second surfaces 11', 12' and curved side faces 15', 16' providing engager parts 35', 36' respectively and receiver parts 25', 26' respectively.

A receiver part 26 of side face 16 of a first component 10 is presented at a first radius from centre C of the component 10, and engager part 36 is presented at a second radius. The second component 10' has an engager part 35' which is also presented at substantially the first radius from the centre of component 10'.

Whilst there may be a slight difference between the radius of engager part 35' and receiver part 26 depending on how tightly stacked the components 10, 10' are to be in use, the engager part 35' of component 10' must not be presented at a radius shorter than that of engager part 36 on component 10.

Thus, in the illustrated embodiment, curved side face 16 of component 10 provides a shoulder for supporting component 10'. In use, when the assembly 1 is in its first configuration engager 35' of component 10' is accommodated in receiver 26 of component 10.

It will be appreciated that the other components 10'' and 10''' are constructed in a similar way so that a receiver part of a larger component may accommodate an engager part of a smaller component.

The central component 100 has opposing circular (rather than annular surfaces) 111 and 112.

Thus, as illustrated in Fig. 1, the components 10, 10', 10'', 10''' and 100 may be arranged in a first orientation (in this case all with their respective narrower surfaces facing upwardly) so that they can pack closely together in a stack.

Turning now to Fig. 2, this illustrates how the assembly 1 may be arranged to adopt a second configuration. Alternate components 10' and 10"' are arranged in a first orientation, as shown in Fig. 1.

However, components 10, 10'' and 100 are inverted to adopt a second orientation. In this way, surfaces 12, 11' of adjacent components 10, 10' and surfaces 11, 12' lie substantially flush. Also, side faces, 16, 15' of components 10, 10' are closely abutting with minimum space between them. In the illustrated embodiment the components are housed in a tray 30.

It will be appreciated that when the assembly 1 is in its second configuration as illustrated in Fig. 2 the components are closely packed to minimise wastage of storage space.

The illustrated components may be assembled into a whole range of articles, such as previously described, by appropriate choice of form and size of the components.

Advantageously, such articles may be sold by a retailer in the second configuration for assembly by the end user into the first configuration.

Turning now to Figs. 3 and 4, there is illustrated a second embodiment of the invention. Fig. 3 shows the embodiment in the second, flush configuration. Fig. 4 shows a first, stacked configuration. Fig. 5 is a plan view of two series of components for this embodiment.

In more detail, there is a first series 40 of generally circular annular components and a second series 50, also of circular annular components. The components in each series 40, 50 are of similar form and crosssection as in the first embodiment. However, the respective series differ in that the first series 40 comprises relatively narrow rings and the second series 50 comprises relative wider rings. Figs. 3 and 4 illustrate a sample assembly 101 constructed from such components.

Suitable components for an assembly as illustrated in these figures may be manufactured by various methods.

For example they may be made by: (a) casting liquid materials into negative moulds to solidify, or (b) cutting and shaping solids with machine or hand tools.

The negative moulds used for casting from liquids in (a) may be first manufactured using the method described herein for cutting and shaping solids in (b), by trenching into a block(s) to the desired depth without full penetration.

The following example concerns use of method (b), for the manufacture of an assembly comprising generally annular components. The assembly comprises a first series of a relatively narrow rings and second series of relatively wide rings, such as illustrated in Figs. 3 to 5. In this case, the components are machined from medium density fibre board. Of course, other materials and techniques may be employed, depending on the proposed use for the assembly.

The example assembly comprises essentially two series of components. Each component has a male (engager) and female (receiver) part in each side face.

Each series of components may be cut from a single sheet of material. To avoid unnecessary variations in the depth of components it may be appropriate to cut both series of components from the same sheet if accuracy is critical and the sizes permit it. The components may be cut using a router having a cutting head as illustrated in Fig. 6 or Fig. 8, for example. The router should be capable of plunging in the material in order to produce closed or nearly closed loops.

Fig. 7 shows in cross-section workpieces for manufacture of the two series of components. The shaded regions illustrate waste material. These are shown for example only. More complex mouldings may have slots or other recesses cut into them prior to their separation in the main process.

Given a sufficiently large work table both series can be cut and shaped from one work-piece. This may be particularly advantageous with CNC routers and their like, some of which may have two or more cutting heads that can operate independently and simultaneously.

Alternatively more than one set of either series may be cut simultaneously where multiple heads work in tandem.

It will be appreciated that the series of narrower rings may need more passes of the cutter to remove all of the waste, unless a separate and larger diameter cutter is used for the smaller series, than is used for the larger series. A CNC router with multiple heads or an automatic tool changing facility would be able to hold both sizes of cutters at the same time.

It should be appreciated that generally cutters will vary slightly in diameter due to manufacturing tolerances and also wear and tear. These differences can be taken into account in a similar manner to the adjustments made for the tightness of fit required between adjacent component, but these anomalies may preclude the use of multiple machine heads if tolerances are critical and the machinery is of an inadequate level of sophistication to compensate.

A suitable jig is required to hold the components once they are released from the apparatus. A jig may comprise sections that can hold the workpiece by vacuum or other mechanical means such as pins. In the latter case the choice of pin type must not present a hazard, should the cutter inadvertently come into contact with it. Alternatively, a jig may have protrusions that interlock with recesses that have been machined into the underside of the workpiece either as a feature of the intended assembly or merely for holding purposes without having any impact on the desired effect of the assembly.

The remaining outer section of the original sheet of material may be either utilised as follows, or designated as waste; (i) the outer section from the second series 50 may form the first part of the assembly and/or the basis of a container box.

(ii) the outer section from the first series 40 may form the first part of another assembly and/or the basis of a container box for that other assembly or any other assembly of different proportions.

(iii)either series may produce waste as narrow replicas of the component parts, dependent on cutter size and overlap; and these may be a useful by-product.

Thus, an assembly may be manufactured with a cutter having a profile as illustrated in Figs. 6 and 8. Cuts are made in accordance with the strategy illustrated in Fig. 7. In this figure the first series has been drawn inverted to portray the compatibility of the two series.

The features illustrated in Fig. 6 are as follows: t = top (maximum) diameter of a cutter b = bottom (minimum) diameter of a cutter r = radius (minimum) at bottom p = overlap of components Thus: p = t - b 2 The following points may assist selection of appropriate cutting points for the cutting head: Incremental distances between centre points of consecutive cuts depend upon the desired width of the component and the diameters of the cutter. The width of components may be represented by adding an excess onto the relevant cutter diameter. In this example it is intended that the initial cut in the first component of the first series will produce a component with an outer edge.

f = first series excess s = second series excess d = distance of increment If both f and s are zero: Then: d = t + 2r d=t+b If either or both of f and s are not zero then a second pass of the cutter will be needed to clear the waste in the respective series.

Incremental distances in the first series: On the first pass of the cutter: d = s On the second pass of the cutter: d = t + b + f Incremental distances in the second series: On the first pass of the cutter: d = t + b + s On the second pass of the cutter: d = f The starting point from the centre of the workpiece will be different for each of the two series as they need to be capable of stacking.

For the first series of components, the distance from the centre of the first cut may be any value, provided that the radius of the cutter is considered.

For example a distance of zero produces a circular hole; a distance of up to the cutter bottom radius produces a circular hole or a slot dependent on the shape desired; and distance greater than the bottom radius of the cutter produces a component with an outer side face. If the distance is not greater than the top radius of the cutter then the outer edge will not be a complete profile, which in itself may be a desired feature for the centre component.

As regards this second series of components, the distance of the first cut of the second series from the centre of the second series is a decremented value of the first cut of the first series: i = initial distance from centre to start first series n = next distance from centre to start second series Then: n = i - p - 2r Thus: n = i - p - b It will be appreciated that the formulae may vary, depending upon the profile of the chosen cutter.

Some example cutters are illustrated in Fig. 8, although clearly a whole host of alternatives are possible. As illustrated in Fig. 8A, the components could have generally flat, inclined side faces. However, provision of protrusions and matching recesses in respective components can be preferable in that it can improve stability of the resultant stack.

The appropriate choice of cutter may also depend upon the materials used for the components. For example, if the material used is prone to damage it may be advisable to provide the components with curved rather than sharply angled side faces. Side faces of the components may include both flat and curved sections, such as would be obtainable with the cutters of Fig. 8C and 8D.

Thus, various different cutters may be selected to form a desired profile on an internal and/or external side face of a component. The assembly may comprise a selection of components having side faces of differing profiles, so long as the components are capable of being stacked together in one or more orientations. Thus, the opposing side faces of one component may be formed of different respective profiles, provided that any components which are to be adjacent the one component in the stacked assembly have respective side faces of matching profile, for example.

Also, it will be appreciated that the assembly may include a selection of components of different shapes, and need not be limited to a series of components of the same general shape and different respective sizes. For example, in the case of a first component which has opposing surfaces and which is to be accommodated between two other components in an assembly, each surface of the first component has an internal and an external boundary.

The external boundary of one surface of the first component is selected to be of a shape matching the internal boundary of a surface of a second component so that the first component may nest closely within the second component. The internal boundary of the other surface of the first component is of a shape matching that of the external boundary of a surface of a third component. In this way the third component may nest closely in the first component in the completed assembly.

Thus, for example, the first component may be selected to have one surface having an external boundary of, say, polygonal shape and an opposite surface may have an internal boundary of, say circular shape. In this way the first component is nestable within a second component which has a surface boundary of polygonal shape and, likewise, the first component may accommodate a third component having a surface boundary of circular shape.

Thus, an assembly of the present invention may comprise a selection of components of various shapes and sizes.

Also various accessories may be used to accompany or be included within the assemblies of the present invention. For example, Fig.2 illustrates provision of a tray which may accommodate and support the illustrated components when the assembly is in the first or second configuration. Other example accessories may be provided with formations capable of interengagement with formations of a component so as to support the component and/or the assembly in a desired configuration. For example an accessory could take the form of a base or stand which has formations arranged to interengage with formations on a component to retain the component at a selected angle relative thereto.Thus, the base or stand may be provided with a channel of a profile capable of mating with a side face of a component so as to receive and retain the component in an orientation generally perpendicular to the base/stand or at any other desired angle, for example.

Also, it will be appreciated that the so-called first configuration of the illustrated assemblies may take various forms. For example, in one first configuration the components may be stacked in an order of increasing size and with the components in a first orientation. Also, some or all of the components may be inverted in a second orientation and the components stacked in the same order to provide an alternative first configuration. Furthermore, the components could be stacked in an order of decreasing size with the components in a first orientation to provide yet another first configuration for the assembly. In addition, some or all of the components may also be inverted and stacked in the same order of decreasing size to provide a yet further first configuration of the assembly.

Various other modifications may be made to the illustrated embodiments.

Claims (15)

1. An assembly of nestable components, the assembly having a first configuration in which at least some of the nested components are stacked and a second configuration in which the nested components lie substantially flush.

2. An assembly according to Claim 1 which includes a first component having formations for supporting a second component stacked thereon to provide the first configuration of the assembly, the second component having corresponding formations arranged so that the respective formations on the first and second components are capable of mating together when the second component is inverted so that the components lie flush to provide the second configuration of the assembly.

3. An assembly according to Claim 2 which includes at least some components having opposing first and second surfaces and one or more side faces adjoining said surfaces, the side faces of the respective components having formations for interengagement with corresponding formations on other components.

4. An assembly according to any preceding claim which includes at least some components having opposing first and second surfaces, each respective surface having an internal and an external boundary, and a first side face adjoining the internal boundaries of the respective surfaces and a second side face adjoining the external boundaries of the surfaces.

5. An assembly according to Claim 3 or 4 wherein at least some of the components have a formation of engager type and a formation of receiver type.

6. An assembly according to any one of claims 3 to 5 which includes components of the same depth and having opposing first and second flat surfaces so that, when in the second configuration, both opposing surfaces of the assembly lie substantially flush.

7. An assembly according to any one of claims 4 to 6 which includes at least some components having opposing first and second surfaces which have non-linear internal and/or external boundaries.

8. An assembly according to any one of claims 4 to 7 which includes a plurality of components having opposing first and second surfaces and wherein the respective internal and external boundaries of the said plurality of components are of the same shape.

9. An assembly according to any one of claims 4 to 8 which includes one or more components having opposing first and second surfaces and wherein the internal boundaries of the surfaces are of different shape to the external boundaries of the surfaces

10. An assembly according to any one of claims 4 to 9 which includes a series of components of different respective sizes and each in the form of a substantially closed loop.

11. An assembly according to Claim 10 which includes at least some components of generally annular shape.

12. An assembly according to Claim 11 which includes at least some components having opposing first and second surfaces which have circular internal and/or external boundaries.

13. An assembly according to Claim 11 or 12 which includes at least some components having opposing first and second surfaces which have polygonal internal and/or external boundaries.

14. An assembly according to any preceding claim further comprising a stand for retaining one or more components of the assembly in a desired configuration.

15. An assembly substantially as hereinbefore described with reference to, and as illustrated in, any one of the accompanying drawings.