WO2011130746A1

WO2011130746A1 - Apparatus and method of recycling an oil drum into furniture

Info

Publication number: WO2011130746A1
Application number: PCT/US2011/032913
Authority: WO
Inventors: Bernhard Koehler; Harry Thaler
Original assignee: Fisker Automotive, Inc.
Priority date: 2010-04-16
Filing date: 2011-04-18
Publication date: 2011-10-20

Abstract

A method of repeatedly forming a seating structure from an oil drum includes the steps of providing a clean oil drum and deforming the oil drum. The oil drum has a first shape having a first base member, an opposed second base member, and a generally planar side wall extending between the first base member and second base member to form a cylindrical first shape. A deforming member is provided for forming the seating structure using a predetermined force. The deforming member is activated to apply the predetermined force to a predetermined location of the oil drum to deform the oil drum side wall such that the oil drum acquires a second shape. The second shape includes a seating portion formed in the oil drum first base member and a back portion formed in the oil drum side wall. A seating surface member is attached to the seating portion.

Description

APPARATUS AND METHOD OF RECYCLING AN OIL DRUM INTO FURNITURE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application

No. 61/325110, filed April 16, 2010, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] The present disclosure relates generally to an apparatus and automated method for forming furniture using a recycled oil drum or the like.

DESCRIPTION OF THE RELATED ART

[0003] Various containers are used in the transport of materials. An example of a container is referred to as a drum. Drums can be made of steel, dense paperboard- commonly called fiber drums, or plastics, and are generally used for the transportation of certain different types of materials, including liquids and bulk goods.

For caustic and acid materials, plastics, usually thermoplastics like Polyethylene,

Nylon, Polystyrene, Polyvinyl chlorides (PVCs) or possibly Polycarbonates are the preferred shipping container; for flammable substances like most petroleum distillates, and alcohol, etc., metal containers are the standard. The selection of material used for shipping non-corrosive industrial chemicals would depend on the chemicals or materials, but the general rule would be to use the container type that is inert or non-reactive with the material being shipped. [0004] It is common for a drum to be referred to as a barrel and the two terms are used nearly interchangeably in the vernacular. Drums such as these can have a standard nominal volume of 55 US gallons (about 208 L) and nominally measure just under 34.5 inches (about 880 mm) tall with a diameter just under 24 inches (about 810 mm) and differ by holding about thirteen gallons more than a Barrel of Crude Oil. in the US, 25-US-gallon (95 L) drums are also in common use and have the same height specification. The standard barrel of crude oil or other petroleum product (abbreviated bbl) is 42 US gallons (about 160 L). Taking account the materials making up the drum, in the vernacular, these three main varieties are known as plastic drums or barrels, cardboard drums or barrels, and steel drums or barrels.

[0005] Drums typically made of steel can have a welded top and ribbed outer wall to improve rigidity and durability. Drums generally define a cylindrical shape with a generally circular top and bottom base members. They are commonly used for transporting oils and fuels, but can be used for storing various chemicals as well. The construction and performance of drums used for shipment of dangerous goods or hazardous materials are strictly governed by United Nations, country, and carrier regulations. These drums are generally cleaned, crushed and disposed of after use. However, the materials used in the drums have a long life, even after disposal. Accordingly, a need exists for alternative uses of oil drums through recycling, particularly after they are used in transporting oil. SUMMARY

[0006] The present disclosure relates to a method of repeatedly forming a seating structure from an oil drum, The method Includes the steps of: (a) providing a clean oil drum, wherein the oil drum has a first shape having a first base member, an opposed second base member, and a generally planar side wall extending between the first base member and second base member to form a cylindrical first shape; (b) providing a deforming member for repeatedly forming the seating structure using a predetermined force, wherein the pressing member includes a receiving portion for receiving the clean oil drum; (c) placing the clean oil drum in the receiving portion of the pressing member; (d) activating the pressing member to apply the predetermined force to a predetermined location of the oil drum to deform the oil drum side wall such that the oil drum acquires a second shape, wherein the second shape includes a seating portion formed in the oil drum first base member and a back portion formed in the oil drum side wall; and (e) attaching a seating surface member to the seating portion formed in the first base member.

[0007] The present disclosure further provides for a method of mass producing seating structures using oil drums. The method includes the steps of: (a) providing a plurality of cleaned oil drums, wherein each oil drum has a first shape having a first base member, an opposed second base member, and a generally planar side wall extending between the first base member and second base member to form a cylindrical first shape; (b) providing a pressing member for repeatedly forming a plurality of seating structures; (c) orienting each of the oil drums in a receiving portion of the pressing member; (d) activating the pressing member to apply a predetermined force to a predetermined location of each of the oil drums to deform each oil drum side wall such that the oil drum acquires a second shape, wherein the second shape includes a seating portion formed in the oil drum first base member and a back portion formed in the oil drum side wall; and (e) attaching a seating surface member to the seating portion formed in the first base member.

[0008] The present disclosure further provides for a mass produceable seating structure including: (a) a clean oil drum having a cylindrical first shape that includes a first base member, an opposed second base member, and a generally planar side wall extending between the first base member and second base member to form the cylindrical first shape, wherein the oil drum acquires a second predetermined deformed shape by orienting the oil drum in a receiving portion of a pressing member and activating the pressing member to apply a predetermined force to a predetermined location of the oil drum such that the second predetermined shape is the same for each seating structure, wherein the second shape includes a seating portion formed in the oil drum first base member and a back portion formed in the oil drum side wall; and (b) a seating surface member secured to a seating portion formed in the first base member.

[0009] Other features and advantages of the present disclosure will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a perspective view of an example seating structure formed from an oil drum according to a method of the present disclosure.

[0011] FIG. 1A illustrates an oil drum prior to deformation.

[0012] FIG. 2 is a back side view of the seating structure of FIG. 1 .

[0013] FIG 3 is a side view of the chair of FIG. 1 .

[0014] FIG. 3A illustrates a cross section of the seating structure of FIG. 3. [0015] FIG. 4 illustrates an example of a deforming apparatus according to the present disclosure.

[0016] FIG. 5 is a flow chart illustrating a methodology of forming a seating structure from an oil drum.

DESCRIPTION

[0017] Referring to FIGS. 1 -3A, an example of a piece of furniture created from recycling an oil drum, such as seating structure 10 of this example, is shown. The piece of furniture can be any type of furniture, such as a table, chair seat or the like, and the selection is non-limiting. The oil drum can be fabricated from any suitable material such as metal and in an example the metal can be steel. The drum, prior to being formed into the chair, has a first use and defines a first shape, which in this example is a cylindrical body enclosing a hollow space. The space allows for filling the drum with a material, such as petroleum or other material that can be contained in a container. The longitudinal body of the drum defines a circular cross section. The cylindrical body defines opposite circular first and second base members, such as lids that are removable or otherwise secured to the body, i.e. or welded shut.

[0018] !n this example, the seating structure 10 is formed from an oil drum 12 (shown in FIG. 1A). Oil drum 12 can define an initial, generally cylindrical first shape, prior to being deformed. The drum includes a generally planer side wall 14 having an external cylindrical surface. The drum 10 also includes a first base member 1 1 located at an upper end of the side wall 14, and an opposed second base member 13 located at a lower end of the side wall. The initial arrangement of the first base member, second base member and side wall forms the cylindrical first shape of the oil drum 12. The oil drum 12 should be suitably clean and may be deformed into a second predetermined shape. In this example, the second shape results in a seating structure 10, although the second shape could be another type of object. The seating structure similarly has a first base member 1 1 and an opposed second base member 13. A side wall 14 extends therebetween the first base member 1 1 and second base member 13.

[0019] In this example, first base member 1 1 is adapted to receive a seating surface 16. For example, the seating surface may be a cushion or the like. The seating surface may be removeably secured to the first base member 1 1 or nonremovable. In this example, second base member 13 is adapted to provide a support for the seating structure, i.e. rest on a floor or ground surface and securely providing stability for seating. In alternative embodiments, wheels or floor pegs can be mounted on base 13 to achieve various desired furniture features. [0020] The predetermined second shape of structure 10 defines a back side 15 and a front side 17, formed ,at least partially, in the sidewall. The front side 17 defines a general inward curvature from the first base member 1 1 to the second base member 13. The curvature of front side 17 is formed during a deformation process of oil drum 12 in a manner to be described. The curve of front side 17 causes an unparallel configuration of first base member 1 1 with respect to second base member 13. Each base member defines a plane. The planes of base members 1 1 and 13 respectively are generally parallel in the oil drum of FIG. 1A, un- deformed first shape. In this example, once they are deformed, the planes of the base members are no longer parallel. First base member 1 1 defines a tilt which can be slight or substantial with respect to second base member 13. This provides for a more desired seating angle.

[0021] Accordingly, in an example where second base member 13 rests on a flat surface such as a floor, first base member 1 1 will define an angled projection towards that flat surface. The desired angle of the projection with respect to second base member 13 allows for a suitable seating position for an individual. Different angles can be formed ranging from steep to shallow for the first base member 1 1 . The angle formed depends on the deformation process. Back side 15 forms an opposite side outward curvature resulting from the deformation process. The curves defined by front side 17 and back side 15 follow along the cylindrical surface 14 as drum 12 is deformed. As shown in FIG. 3A, the cross section 3A-3A from the oil drum of FIG. 3, the curves of front side 17 and back side 15 follow a similar trajectory allowing for the angled slope of first base 1 1 .

[0022] FIG. 4 illustrates an example deforming member 40. Deforming member 40 can be a press used in a manufacturing environment to form a material having a first predetermined shape into an object having a second predetermined shape. An example of a first predetermined shape is a cylinder having a flat or smooth wall . The press includes a frame 41 having a receiving cavity 42 for receiving and supporting the drum. Cavity 42 is sized and shaped to receive a drum 12. in another example, the cavity may support a plurality of drums, so that multiple objects may be formed concurrently. The frame 41 includes a receiving area or cavity 42 for receiving the drum in an upright position, although other positions may be used depending on the desired second shape. The frame 41 also includes a pressing member 44 secured thereto the frame 41 that is spaced a first predetermined distance from a receiving portion of the oil drum 12. The pressing member 43 is moveable in order to compress the drum. Similarly, a portion of the frame may be movable to press the oil drum 12 against the pressing member 44. The pressing member 44 may be a relatively heavy mechanical apparatus that applies pressure to the drum 12 at a predetermined location thereof, such as from above or against a base member or side wall of the drum.

[0023] The pressing member 44 applies a predetermined force to drum 12. The pressing member 44 can be referred to as a tool and includes a pressing head 43 for contact with the drum 12. The pressing head can have various linear and non-linear shapes, depending on the desired second shape. The geometric relationship between the pressing member 44 and pressing head can be varied depending on the desired second shape. The pressing head may be removable to easily change the second predetermine shape of the object. The head 43 is adjustable in the cavity for a predetermined applying force to the drum 12. In addition, the head 43 may be adjustable to apply the force at various predetermined angles, to form the drum to according to the desired second shapes. Moreover, head 43 can define various geometries such as circular or rectangular to form unique shapes of the deformed drum 12. It should be recognized that the selection of head shape is non- limiting.

[0024] The direction of the applied force to the oil drum12 is illustrated by directional arrows 46. The apparatus can further include a computer for entering a crushing program or instructions. The program can further include various shapes that a user desires to form based on predetermined crushing or deformation instructions. For example, if a user chooses to form a short chair with a shallow seating angle, then the program will apply the appropriate pressure to the drum to form the desired shape. A different force application would be applied if the user chooses to form a taller seating surface with a steeper seating angle for example. The angle of applied force with respect to an axis of the drum may be varied to obtain the desired shape of the seating apparatus.

[0025] FIG. 5 illustrates a flow chart of an example methodology of forming an article such as the seating structure according to the present example. The methodology begins in box 100, and the drum 12 having a first predetermined shape is provided. The drum is cleaned, it is desired to provide a drum free from toxic chemicals, particularly petroleum and any associated by products. The oil drum 12 can be brand new (i.e., prior to receiving any chemical material for transport) or recycled from being used to transport materials such as oil or the like, !f the drum was previously used to transport or contain oil or another material, it is first cleaned using any conventionally available oil cleaning process. In an example, a cleaning process includes a solvent adapted to extract the oil or break-up the oil material from the surface of the metal drum. High pressure blasting techniques are also available. The drum can be cleaned to be substantially free from petroleum or any byproducts or residue such that it can be suitable for human interaction.

[0026] The methodology advances to box 1 10 where a furniture shape, or second shape of structure 12 is determined. Seating structure 12 defines a second shape, which is generally that of a chair or the like having an angled seating portion and a vertically oriented back portion. Once a desired shape is determined, the methodology advances to box 130 where the seating structure is formed by deforming the cylindrically shaped drum. The seating apparatus may be formed using a variety of deforming techniques, such as a press as previously described. In an example, the deforming technique is automated to form a plurality of seats having a generally predictable, uniform configuration upon completion.

[0027] For example, the drum is positioned in the receiving portion of the press, where it is held in place during operation. A plurality of drums may be located in the receiving portion of the press to further automate the process. Deformation of a steel drum results from applying a force to a predetermined surface of the oil drum 12 by a pressing member 43, as previously described. For example, a predetermined force 46 may be applied at either the first base member or second base member. In another example, a predetermined force may be applied to the drum by moving the drum to be in contact with a stationary pressing member. In another example, multiple forces may be applied concurrently or in series to the steel drum, i.e. such as by applying a force to both base members. The deformation can be characterized as a crushing of the drum which causes a bending movement of the cylindrical surface in various directions. Either of the base members of the oil drum may be crushed to form unique bends in the side wall of the cylinder resulting in the second predetermined shape. Advantageously, selection of the degree of predetermined force and shape of the pressing member provide for repeatability in obtaining the second predetermined shape. FIGS. 1 -3A illustrate various curves and bends resulting from a crushing process.

[0028] The methodology can include an optional programmable step in box 120. In this example, the crushing and deformation can be predetermined and automated. The force of the pressing member can be applied until the upper base of the drum reaches a vertical level that allows a person to sit down on the upper base. In the example as shown in FIGS. 1 -3A, the upper base can be angled relative to ground and forming a cavity adapted to allow for sitting.

[0029] Using the described methodology, various shapes of the crushing process can be formed according to a predetermined pattern or technique. The applied pressure can be set to deliver force by the pressing member for a predetermined time period or a predetermined force quantity, in a further example, the crushing process is performed in a crushing apparatus that includes a crushing cavity for receiving a drum and force pads on opposite ends of the drum, Each force pad can be used to deliver force to the drum and cause deformation.

[0030] After the deformation step of box 130, the methodology advances to box 140 where a seating member is attached to the deformed drum. In an example, the seating member is leather seat and formed to fit into the upper base end of the drum to form the seating portion. In a further example, the seating member is a cushion. Any suitable seating member can be attached to the deformed drum, in an even further example, the seating member is attached in an automated process immediately following the deformation process. The seating member may be removeably retained to the deformed drum, or permanently fixed using a suitable technique, such as an adhesive or a fastener.

[0031] While in the example, the method describes the formation of a chair, other types of objects are contemplated, such as a bench, a table, a stool or the like. The deformed drummed can be finished using a suitable technique, such as painting, plating or the like according to any aesthetic effect desired.

[0032] Many modifications and variations of the present disclosure are possible in light of the above teachings. Therefore, within the scope of the appended claim, the present disclosure may be practiced other than as specifically described.

Claims

WHAT IS CLAIMED IS:

1 , A method of repeatedly forming a seating structure from an oil drum, said method comprising the steps of:

(a) providing a clean oil drum, wherein the oil drum has a first shape having a first base member, an opposed second base member, and a generally planar side wall extending between the first base member and second base member to form a cylindrical first shape;

(b) providing a deforming member for repeatedly forming the seating structure using a predetermined force, wherein the deforming member includes a receiving portion for receiving the clean oil drum;

(c) placing the dean oil drum in the receiving portion of the deforming member;

(d) activating the deforming member to apply the predetermined force to a predetermined location of the oil drum to deform the oil drum side wall such that the oil drum acquires a second shape, wherein the second shape includes a seating portion formed in the oil drum first base member and a back portion formed in the oil drum side wall; and

(e) attaching a seating surface member to the seating portion formed in the first base member.

2, The method of claim 1 wherein the deforming member is a press.

3, The method of claim 1 further comprising the step of cleaning the oil drum prior to placement into the deforming member.

4. The method of claim 1 wherein the predetermined force is applied at a predetermined angle with respect to the oil drum side wall.

5. The method of claim 1 wherein the predetermined force is applied for a predetermined period of time to repeatedly deform each oil drum and acquire the second shape of the seating structure.

6. The method of claim 1 wherein the predetermined force is applied to deform a front portion of the oil drum that curves inward forming an angle of curvature between the first base member and second base member, such that the first base member is in a non-parallel configuration with respect to the second base member.

7. The method of claim 1 wherein the seating surface defines a concave shape curving inward toward an internal cavity of the oil drum.

8. The method of claim 1 wherein the seating surface is sized and shaped to allow for seating of an individual user.

9. The method of claim 1 wherein the second base member is sized and shaped to provide a support surface for the seating structure.

10, The method of claim 1 wherein the seating structure defines a chair.

11 , The method of claim 1 wherein the oil drums are recycled oil drums.

12, A method of mass producing seating structures using oil drums, said method comprising the steps of:

(a) providing a plurality of cleaned oil drums, wherein each oil drum has a first shape having a first base member, an opposed second base member, and a generally planar side wall extending between the first base member and second base member to form a cylindrical first shape;

(b) providing a pressing member for repeatedly forming a plurality of seating structures;

(c) orienting each of the oil drums in a receiving portion of the pressing member;

(d) activating the pressing member to apply a predetermined force to a predetermined location of each of the oil drums to deform each oil drum side wall such that the oil drum acquires a second shape, wherein the second shape includes a seating portion formed in the oil drum first base member and a back portion formed in the oil drum side wail; and

13, The method of claim 12 wherein the predetermined force is applied at a predetermined angle with respect to the oil drum first base member.

14, The method of claim 12 wherein the predetermined force is applied at a predetermined angle with respect to the oil drum side wall .

15, The method of claim 12 wherein the predetermined force is applied for a predetermined period of time to repeatedly deform each oil drum and acquire the second shape of the seating structure.

16, The method of claim 12 wherein the predetermined force is applied to deform a front portion of the oil drum that curves inward forming an angle of curvature between the first base member and second base member, such that the first base member is in a non-parallel configuration with respect to the second base member.

17, The method of claim 12 wherein the seating surface defines a concave shape curving inward toward an internal cavity of the oil drum.

18, The method of claim 12 wherein the second base member is sized and shaped to provide a support surface for the seating structure.

19. The method of claim 12 wherein the seating structure defines a chair.

20. A mass produceable seating structure comprising:

(a) a clean oil drum having a cylindrical first shape that includes a first base member, an opposed second base member, and a generally planar side wall extending between the first base member and second base member to form the cylindrical first shape, wherein the oil drum acquires a second predetermined deformed shape by orienting the oil drum in a receiving portion of a pressing member and activating the pressing member to apply a predetermined force to a predetermined location of the oil drum such that the second predetermined shape is the same for each seating structure, wherein the second shape includes a seating portion formed in the oil drum first base member and a back portion formed in the oil drum side wall; and

(b) a seating surface member secured to a seating portion formed in the first base member.