WO2012032517A1

WO2012032517A1 - Strengthening element for an object and method of manufacture thereof

Info

Publication number: WO2012032517A1
Application number: PCT/IL2011/000717
Authority: WO
Inventors: Menachem Tzor
Original assignee: Keter Plastic Ltd.
Priority date: 2010-09-07
Filing date: 2011-09-07
Publication date: 2012-03-15

Abstract

A strengthening element for an object, the element includes a strengthening portion (15) and a reinforcing member (38) attached thereto. The strengthening portion (15) includes a longitudinal opening for removing a mold there from. The reinforcing member is configured to structurally reinforce the strengthening portion (15), thus providing the object with an additional strength and stability.

Description

STRENGTHENING ELEMENT FOR AN OBJECT AND METHOD OF

MANUFACTURE THEREOF

FIELD

The subject matter of the present application relates to a reinforced object and method of manufacture thereof, and in particular to a reinforced object comprising a Hollow Section Profile.

BACKGROUND

Objects of all types, and in particular, load-bearing objects, are produced for use in a variety of settings.

To reduce the amount of material needed to produce such object and/or the weight of the object, it can be formed with a Hollow Section Profile (HSP).

Due to the hollow nature thereof, an object having a HSP can sometimes require reinforcement to withstand load forces thereon caused by other objects, or for structural support unrelated to other objects.

Even objects which are not formed with a HSP may need reinforcement. For example when such object is designed to withstand load forces, or such object is elongated.

SUMMARY

In accordance with one aspect of the subject matter of the present application, there is provided an object comprising a strengthening portion and a reinforcing member attached thereto; the reinforcing member being configured to structurally reinforce the strengthening portion.

It will be understood that the object can be any object requiring reinforcement. For example the object can be elongated objects and/or objects designed to bear loads, such as a shelf, door, toilet seat, seat, arm rest, back rest, slide, shelter, storage unit or table (legs or table portion thereof).

The strengthening portion can comprise at least one wall. The strengthening portion can comprise at least two walls extending in different directions and joined along a merging edge thereof. The strengthening portion can comprise a plurality of connected walls. In such case, the strengthening portion can comprise two parallel walls and a single transverse wall joining the two parallel walls. It will appreciate that the walls can be slightly slanted, as will be clear from the drawings described hereinafter. Such joining can be between the edges of the two parallel walls, such that a substantially U-shaped cross section of the two parallel walls and the transverse wall is formed. Alternatively the strengthening portion can comprise two parallel walls and more than one transverse wall joining the two parallel walls. The strengthening portion can comprise walls forming at least a section thereof with a HSP.

According to one example the strengthening portion includes a quadrangular structure having a longitudinal opening which is substantially covered with the reinforcing member.

The strengthening portion can be integrally formed as a single unit. For example, the strengthening portion can be a molded object. Such molded object can be made in a single molding operation.

The strengthening portion can be made of a homogenous material.

The strengthening portion can be made of polymeric material. For example, the strengthening portion can be made of polypropylene (PP).

A wall of the strengthening portion can comprise a surface and a projection extending from the surface and configured to constitute, together with the surface, a seating section for at least a part of the reinforcing member. In such case, another wall, spaced from the aforementioned wall, can comprise a corresponding surface and projection configured to constitute together with the surface, a seating section for another part of the reinforcing member, such that the reinforcing member, when secured to the seating, forms a bridge-like portion between the two surfaces. In such case, the strengthening portion can comprise a transverse wall joining the two walls, disposed spaced from the reinforcing member. Such arrangement can be used to form a HSP which is partly constituted by the strengthening portion and partly constituted by the reinforcing member.

The strengthening portion can constitute a majority of the volume of the object.

The strengthening portion can constitute 80 to 95 percent of the volume of the object. The strengthening portion can constitute a majority of the mass of the object. The strengthening portion can constitute between 80 to 95 percent of the mass of the object.

A wall of the strengthening portion can be formed with a recess configured to constitute a seat for at least a part of the reinforcing member.

A wall of the strengthening portion can be formed with a slot configured to receive at least a part of the reinforcing member therein.

The strengthening portion can comprise a surface and at least one projection extending therefrom. The projection can be integrally formed with the strengthening portion. The projection can be made of the same material as the remainder of the strengthening portion.

The strengthening portion can comprise a surface having peripheral edges, at least one peripheral wall extending from at least one of the peripheral edges, and at least one rib extending from the at least one peripheral wall and engaging the surface to provide structural support thereto. The at least one rib can extend adjacent to a portion of the surface, or from one of the walls extending from one peripheral edge of the surface to another of the walls extending from the peripheral edge of the surface. The ribs can be parallel with a longitudinal or transverse dimension of the object.

The reinforcing member can be attached to an outer surface of the strengthening portion. The reinforcing member can be attached to, and extend between, spaced walls of the strengthening portion. In such case, each of the walls can be formed with a depression at one end thereof, configured as a seat for the reinforcing member.

The reinforcing member can comprise one or more reinforcement elements.

The reinforcement elements can be a ribbon and can be elongated. The ribbon can have a rectangular-shaped cross section.

Each reinforcement element can comprise a plurality of fibers. In such case, the reinforcement element can further be embedded in a matrix to hold the fibers together. The matrix can be made of thermoplastic material.

The fibers can be endless, short, or long fibers. It will be appreciated that fibers having tensile and/or compressive strength greater than that of the material, from which the strengthening portion is composed, can be used for the reinforcement element. For example, the strengthening portion can be made of polymeric material, such as polypropylene, and the reinforcement element can comprise fiberglass or carbon fibers. The matrix can be made of, for example polypropylene or polyethylene. In any case the matrix must be of a material compatible for welding to the material of the strengthening portion.

The reinforcement elements can be attached to different sections of the strengthening portion. The reinforcement elements can be attached to opposing walls of the strengthening portion.

The reinforcing member can be sized and disposed to close a gap between opposing walls of the strengthening portion in a lid-like arrangement. To elaborate, the strengthening portion and reinforcing member can be attached in a box-lid arrangement, wherein the reinforcing member provides a lid-like covering between two spaced portions of the strengthening portion. In a case where the reinforcing member comprises a plurality of reinforcement elements, two such reinforcement elements can be arranged such that they each close different gaps of the strengthening portion. In such case the two reinforcement elements can extend parallel with respect to each other.

The different gaps can be disposed on opposing sides of the strengthening portion. For example, the gaps can be disposed on the upper and lower sides of the strengthening portion. In a case where the reinforcement elements are attached to first and second opposing sides of the strengthening portion, the first side can have a greater amount of reinforcement than the second side. The first side can be the uppermost side of the object. The first side can be the side of the object configured to bear a load thereon.

It will be understood that such asymmetric arrangement of the reinforcement can be carried out in different ways. For example one side could have a greater number of reinforcement elements attached thereto, and all of the reinforcement elements are identically sized. Alternatively, each side could have the same number of reinforcement elements, but the reinforcement elements are not identically sized.

It will be appreciated that such asymmetric arrangement can be used to take advantage of properties of material used in the reinforcing member.

According to another aspect of the subject matter of the present application, there is provided a method of manufacturing a reinforced object having a molded strengthening portion, including;

(a) placing a reinforcement element on the strengthening portion; and (b) attaching at least one edge of a reinforcement element to the strengthening portion via laser welding.

The method can comprise a step before step (a), of removing the molded strengthening portion from a mold.

The method can comprise a step before step (a), of forming the molded strengthening portion with at least one seat configured for holding at least a portion of the reinforcement element.

It will be understood that some of the advantages of the reinforced object and method of manufacture above can include:

- the mold of strengthening portion can be easily removed through an longitudinal opening.

- The strengthening portion can be flat, or free of warps, in the area to which the reinforcing member is attached.

- The reinforcing member can be consistently and precisely attached to a desired are of the strengthening portion.

The present aspect can include any of the features mentioned above in connection with the previous aspect.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the subject matter of the present application and to see how it can be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

Fig. 1 is a perspective view of a shelving unit comprising objects (constituted by shelves) in accordance with an example of the subject matter of the present application;

Fig. 2A is a top perspective view of one of the shelves in Fig. 1 ;

Fig. 2B is a top perspective view of one of the shelves in Fig. 1 with the reinforcing ribbons removed;

Fig. 3A is a bottom perspective view of the shelf in Figs. 1 and 2;

Fig. 3B is a bottom perspective view of the shelf in Figs. 1 with the reinforcing ribbons removed;

Fig. 4 is a perspective sectional view, taken along cross section A-A in Fig. 2A with one of the reinforcement elements being removed; Fig. 5 is an enlarged perspective view of a portion of the strengthening element of Fig. 4; and

Fig. 6 is a perspective sectional view of a portion of an object in accordance with another example of the subject matter of the present application. DETAILED DESCRIPTION OF EMBODIMENTS

Referring now to the drawings wherein like reference characters designate like or corresponding parts throughout several views, with reference to Fig. 1, there is illustrated a shelving unit, generally designated as 10. The shelving unit 10 comprises five identical shelves, each designated as 12. Each shelf 12 has a rectangular shape, and comprises a top surface 14 for supporting objects (not shown), and four peripheral side walls (16, 18) extending downwardly from the surface 14.

The side walls include two opposing longitudinal side walls 16 and two opposing transverse side walls 18. The surface 14 is formed with an aperture 20 adjacent each corner 22 thereof. At least one supporting member 24 is fitted to each aperture 20, to facilitate suspension of the shelves 12 in their positions.

Referring now to Figs. 2A-3B, the shelf 12 will be described in more detail. As best seen in Fig. 2A, the shelf 12 comprises two side strengthening elements 26 and optionally a central strengthening element 28, extending between the two opposing transverse side walls 18. Side strengthening elements 26 are disposed alongside the longitudinal side wall 16, and central strengthening element 28 is disposed substantially at the center of shelf 12.

It will be noticed that according to one example the peripheral side walls (16, 18) extend continuously from each corner. In other words, each side wall is free of an opening formed therein.

As shown in Fig. 3B, each strengthening element includes a strengthening portion, here illustrated as a quadrangular structure 15 protruding toward the bottom of shelf 12, and can further include a plurality of transverse ribs 36 disposed inside the quadrangular structure 15. As most clearly shown in Fig. 2B, the quadrangular structure 15 includes a longitudinal opening 17 from one side thereof, here illustrated as the side facing top surface 14 of shelf 12. Each strengthening element 26 and 28, further includes a reinforcing member, here illustrated as a ribbon 38 disposed on the opening seated on opening 17 in such a way so as to form one horizontal surface together with the top surface 14 of shelf 12. Notably, all of the reinforcement ribbon 38 can be attached to the quadrangular structure 15 and to top surface 14 via laser welding. Welding the reinforcing ribbon 38 to the strengthening elements 26 and 28, provides the shelf 12 with additional strength and stability. Forming the quadrangular structure with opening 17, however, allows for saving manufacturing cost, by utilizing a mold which can be easily removed through the longitudinal opening. Due to the reinforcing ribbon covering the opening 17, the stability of the shelf 12 is not compromised.

Quadrangular structure 15 can be a complete structure, or alternatively can include a plurality of apertures 31. These apertures 31 can be formed in the walls of the quadrangular structure 15, so as to minimize the amount of material used during the manufacture of the shelf 12, thus reducing the cost and the weight thereof. It is appreciated that the quadrangular structures 15 can alternatively be any other strengthening structure being a strengthening portion, for example rectangular structure, triangular structure, trapezoid structure, a semi circular structure etc. The ribbon being a reinforcing member, is thus, configured to serve as a lid covering the strengthening structure and adding strength and stability thereto.

Referring to Fig. 3A, shelf 12 can further include a rib arrangement 35 at the bottom thereof, defined alongside the transverse side walls 18. Rib arrangement 35 can include one or more transverse ribs 37 extending along the width of shelf 12, and a plurality of longitudinal ribs 32 i.e. ribs extending along a longitudinal dimension of the shelf 12, extending between the transverse ribs 37. Additionally, the bottom of shelf can comprise other transverse ribs 37a extending between the various rectangular structures 15.

According to the illustrated embodiment the shelf 12 further comprises an additional quadrangular structure 19 defined between the inside of longitudinal wall 16, and the outside of the adjacent quadrangular structure 15. The additional quadrangular structure 19 includes a bottom facing opening 17a, and can be reinforced by ribbons 38a disposed thereon, and can include a plurality of transverse ribs 36a. The ribbon 38a can be welded to the rectangular structure for example by utilizing laser. As clearly seen in Fig. 2A when the shelf 12 is assembled ribbons 38 constitute part of the top surface 14, while, ribbon 38a are disposed at the bottom thereof. This way, the reinforcing ribbons 38 and 38a together with the quadrangular structures provide the longitudinal side wall 16 of the shelf 12 with strength and stability.

With particular reference to Figs. 4 and 5, further details of the quadrangular structures 15 and 19 will be described.

The longitudinal side wall 16 comprises an upper edge 41, a lower edge 42 and a central portion 44 extending therebetween. The lower edge 42 comprises a shoulder 46 which extends away from the central portion 44 and constitutes a seat 43A at the bottom of shelf 12, for holding ribbon 38a, therein. A horizontal section 50 extends from the upper edge 41, in a direction substantially perpendicular to the central portion 44. The horizontal section 50, which forms the periphery of top surface 14, is recessed at an end 48 thereof, spaced from the upper edge 41, to form a portion of seat 40 at the top surface 14 of the shelf 12 for holding ribbon 38.

Notably, the horizontal section 50 forms a bridge portion between a longitudinal wall 16 and a longitudinal rib 34a. One face of longitudinal rib 34a serves as the side wall of the quadrangular structure 15 while the other face thereof serves as the side wall of quadrangular structure 19. The longitudinal rib 34a has an uppermost edge 52, a lowermost edge 54 and a central section 56 extending therebetween. The uppermost edge 52 is integrally formed with the end 48 of the horizontal section 50. The lowermost edge 54 is coupled to an additional horizontal section 58, which extends transversely therefrom, and serves as the bottom portion of quadrangular structure 15.

The additional horizontal section 58 extends to another longitudinal rib 34b, which serves as the side wall of the quadrangular structure 15. Longitudinal rib 34b includes a downwardly extending external rib 60, which together with shoulder 46 defines seat 43a for holding ribbon 38a covering both the opening 17a of quadrangular structure 19 and the bottom of quadrangular structure 15. It is appreciated that ribbon 38 can alternatively be configured to cover only the opening 17a of quadrangular structure 19.

The longitudinal rib 34b further includes an uppermost edge 68 which is integrally formed with the upper surface 14 of the shelf 12. It is noticed that the engagement of the upper edge 68 with the upper surface 14 includes a recessed portion 70, which together with the recess at an end 48, form seat 40 for holding ribbon 38.

The reinforcement ribbons 38 and 38a are mounted on the quadrangular structure 15 and 19, respectively, and can be welded thereto via laser welding. Alternatively, the reinforcement ribbons can be mounted, glued fastened in any other known methods. It can be seen that the reinforcement ribbons 38 and 38a close the opening formed by the side walls of quadrangular structure 15 and 19, thus constituting a lid-like structure, and thereby forming a full strengthening structure for providing longitudinal side walls 16 with the necessary strength and durability.

The shelf 12 can be manufactured in the following manner. The reinforcement ribbons 38 and 38a are produced in an extrusion process where endless fibers are embedded in a matrix material to hold them together.

A strengthening portion of the shelf 12, i.e. all elements illustrated except for the reinforcement ribbons 38 and 38a, however including the quadrangular structures 15 and 19, is formed in a single mold. The strengthening portion is then removed from the mold. It is appreciated that since the quadrangular structure 15 and 19 include longitudinal openings 17 and 17a respectively, the mold can be removed easily, as opposed to a mold which is removed from strengthening structure comprising a full quadrangular structure without a longitudinal opening. Each reinforcement ribbons 38 and 38a is placed on a seat formed on the strengthening portion (i.e. seats 40 and 43a, as explained hereinabove), and attached thereto, by joining the edges of the strengthening elements to the strengthening portion thereunder via laser welding.

It will thus be appreciated that the side wall 16, together with the quadrangular structures 15 and 19 including the longitudinal ribs (34a, 34b), and transverse horizontal sections (50, 58) are integrally formed to constitute a single integral unit.

A further example (not shown) can include reinforcing ribbon attached to an outer surface of a strengthening portion and not seated on a recess, or within a slot of one of the sides thereof.

Yet another example (not shown) could include the reinforcement ribbon being attached to an outer surface of the side wall or in a groove formed only in the side wall and not the upper and lower sections of the object. For example, with reference to Fig. 5, the side wall 16 could have a reinforcing member, such as a ribbon attached thereto, or instead thereof. In such case the reinforcement elements (38, 38a), could be absent.

It is appreciated that the ribbon can be replaced with any other reinforcing member such as metal rods, a grid having a reinforcing material etc. In addition, the ribbon can include a plurality of ribbons and/or other reinforcing member mounted on the strengthening portion thus providing thereto additional strength and stability. Still another example is seen in Fig. 6, which shows a section of another object, generally similar to the first object.

Referring now to Fig. 6, the object, generally designated as 100, comprises an upper wall 102, a side wall 106, ribs (108A, 108B, 108C), a horizontal section 104 extending between the ribs (108B, 108C), and an end wall 110.

The object 100 illustrates an example of a strengthening structure in a form of a box and with a reinforcing ribbon which serves as a lid-like enclosure over a gap.

One such box is constituted by ribs 108A and 108B together with the horizontal section 104. The lid in this case being the reinforcement ribbon 112 which seals the box from above, by attachment thereof to a recess 114 formed in upper wall 102, similar to the previous example shown in Figs. 2 A to 5.

Another such box is constituted by horizontal section 104 together with the end wall 110 and a portion 102 A of the upper wall 102. The lid in this case being the reinforcement ribbon 116 which seals the box from above, by attachment thereof to lower surfaces of the horizontal section 104 and end wall 110. As can be clearly seen in this case, the ribbon 116 does not cover the bottom of horizontal section 104, as in previous example.

It will be appreciated that an advantage can be achieved with the type of construction described above, namely that an object made of polymeric material can be formed in a single uncomplicated molding process, and a closed box and lid formation can be achieved via the application of a reinforcement ribbon to the gap of the polymeric object, thereby providing a reinforced object having a relatively low weight when compared to an object having a closed box formation, i.e. a polymeric object having a normal HSP i.e. for rectangular four walls constituting a rectangular shape.

Claims

CLAIMS:

1. A strengthening element for an object the element comprising a strengthening portion and a reinforcing member attached thereto; the reinforcing member being configured to structurally reinforce the strengthening portion.

2. The strengthening element of claim 1, wherein the strengthening portion includes a wall, the wall comprising a surface and a projection extending from the surface and configured to constitute, together with the surface, a seating section for at least a part of the reinforcing member.

3. The strengthening element of claim 1 or 2, wherein the strengthening portion includes a wall, the wall being formed with a recess configured to constitute a seat for at least a part of the reinforcing member.

4. The strengthening element of any one of claims 1 to 3, wherein the strengthening portion includes a wall, the wall being formed with a slot configured to receive at least a part of the reinforcing member therein.

5. The strengthening element of any one of claims 1 to 4, wherein the strengthening portion includes a quadrangular structure having a longitudinal opening configured to be covered at least by a portion of the reinforcing member.

6. The strengthening element of any one of claims 1 to 5, wherein the reinforcing member is attached to different sections of the strengthening portion.

7. The strengthening element of claim 6, wherein the reinforcing member is attached to opposing walls of the strengthening portion.

8. The strengthening element of any one of claims 1 to 7, wherein the reinforcing member is a ribbon sized and disposed to close a gap between opposing walls of the strengthening portion in a lid-like arrangement.

9. The strengthening element of claim 8, wherein the reinforcing member comprises a plurality of reinforcing ribbons, two such reinforcing ribbons being arranged such that they each close different gaps of the strengthening portion.

10. The strengthening element of claim 9, wherein the different gaps are disposed on opposing sides of the strengthening portion.

11. The strengthening element of claim 10, wherein the gaps are disposed on the upper and lower sides of the strengthening portion.

12. The strengthening element of any one of claims 1 to 11, wherein the reinforcing member is attached to first and second opposing sides of the strengthening portion, the first side having a greater amount of reinforcement than the second side.

13. The strengthening element of claim 12, wherein the first side is the uppermost side of the object.

14. The strengthening element of any one of claims 1 to 13, wherein the strengthening portion comprises a surface having peripheral edges, at least one peripheral wall extending from at least one of the peripheral edges, and at least one rib extending from the at least one peripheral wall and engaging the surface to provide structural support thereto.

15. The strengthening element of claim 14, wherein the at least one rib extends adjacent to a portion of the surface, or from one of the walls extending from one peripheral edge of the surface to another of the walls extending from the peripheral edge of the surface.

16. The strengthening element of any one of claims 1 to 15, wherein the reinforcing member is attached to an outer surface of the strengthening portion.

17. A method of manufacturing a reinforced object having a molded strengthening portion, including;

(a) placing a reinforcing member on the strengthening portion; and

(b) attaching at least one edge of a reinforcing member to the strengthening portion via laser welding.

18. The method of claim 16, further comprising a step before step (a), of removing the molded strengthening portion from a mold.

19. The method of claim 16 or 17, further comprising a step before step (a), of forming the molded strengthening portion with at least one seat configured for holding at least a portion of the reinforcing element.

20. The method of claim 19 wherein the step of forming the molded strengthening portion further comprising forming a longitudinal opening therein.

21. The method of claims 19 or 20 wherein the step of forming the molded strengthening portion includes integrally forming the strengthening portion with the reinforced object.

22. An object having a strengthening element, the strengthening element comprising a strengthening portion and a reinforcing member attached thereto; the reinforcing member being configured to structurally reinforce the strengthening portion.

23. The object of Claim 22 wherein the strengthening element includes quadrangular structure.

24. The object of Claim 22 or 23 wherein the strengthening element includes a longitudinal opening, and wherein the reinforcing member is a ribbon being configured to substantially cover said longitudinal opening.

25. The object of Claim 22 wherein the strengthening element is integrally formed with the object, and the wherein the reinforcing member is welded to the strengthening element.