Patent Application
20250010803
This invention pertains generally to the field of metal fabricating, particularly of metal boxes. This invention pertains particularly to the field of fabricating backpack boxes used for work vehicles, which are commonly used for retaining tools and materials employed at work sites.
Backpack truck boxes are commonly known for use with work vehicles such as pickup trucks, stake body trucks, dump trucks the like. As shown in
In one embodiment shown in
As shown particularly in
The typical construction of the backpack truck box 10 as described hereinabove requires a great deal of welding. This is resource-intensive and requiring a large number of work hours in order to construct a truck box 10. This adds considerably to the complexity and expense of manufacture, resulting in higher product cost for the end user. Moreover, additional operational costs are encountered in other manufacturing steps.
As shown in
Provided in this disclosure is a method of fabricating a backpack truck box, including a step of forming first and second patterned members from sheet material. Each of the patterned members are formed by a plurality of edges defining a first panel and a second panel, each of which have one or more pairs of opposing tabs formed contiguously on opposing edges of each of the first and second panels. One or more bending operations are performed upon each of the opposing tabs to form first and second side portions extending at a predetermined angle from each of the first and second panels. The side portions of the first panel are welded together to respective corresponding side portions of the second panel to produce a welded backpack truck box housing.
In an exemplary embodiment, the forming of the first and second patterned members includes forming each panel into a two-dimensional shape of a semi-truncated rectangle with at least a pair of rectangular opposing tabs. This results in a backpack truck box housing having a three-dimensional shape of a semi-truncated rectangular prism. The plurality of edges of each panel can include first and second opposing parallel edges and first and second opposing sloped edges. The rectangular opposing tabs can be tabs formed respectively on each of the respective opposing parallel and sloped edges. The step of performing the bending operation(s) can include forming side portions along each of the first and second opposing parallel edges and first and second opposing sloped edges.
In another exemplary embodiment, the performing of the bending operation(s) can include performing a plurality of bending operations upon each of the opposing tabs to form perpendicular side portions each having perpendicularly-extending rectangular gutters. These gutters each define a partial perimeter into an internal volume of the backpack truck box housing. Preferably, doors can be attached to the respective partial perimeters for enclosing the internal volume of the backpack truck box housing. Further, the step of welding can include welding a middle portion between the side panels to define a width of the backpack truck box housing. Additionally, a top portion can be welded onto the backpack truck box housing. Moreover, one or more shelves can be assembled within the backpack truck box housing. Alternatively, no shelves can be used, and adjustable shelves can be used. Any shelves can be welded in place.
Another exemplary embodiment of the present method of fabricating a backpack truck box can include forming first and second patterned members from sheet material. Each of the patterned members include first and second opposing parallel edges and first and second opposing sloped edges thereby defining a first panel and a second panel each having a two-dimensional shape of a semi-truncated rectangle. The patterned members include rectangular tabs formed respectively contiguously on the respective opposing parallel and sloped edges of each of the first and second panels. One or more bending operations are performed upon each of the rectangular tabs to form parallel and sloped side portions. These side portions extend perpendicularly from each of the first and second panels respectively along each of the first and second opposing parallel and sloped edges. A middle portion is welded between the parallel and sloped side portions of the first panel to respective parallel and sloped side portions of the second panel to produce a welded backpack truck box housing. A top portion is welded onto the backpack truck box housing.
In another exemplary embodiment, the performing of the bending operation(s) includes performing a plurality of bending operations upon each of the opposing tabs to form perpendicular side portions each having perpendicularly-extending rectangular gutters that each define a partial perimeter into an internal volume of the backpack truck box housing. A door is attached to one or more partial perimeters for enclosing the internal volume of the backpack truck box housing.
According to one aspect, the method of the invention considerably reduces the amount of welding required to manufacture a backpack truck box.
According to another aspect, the method of the invention is less resource-intensive and reduces the number of work hours and resources required to construct a truck box.
According to still another aspect, the method of the invention reduces the complexity and expense of needed for manufacturing a truck box, resulting in a reduction in product cost that can be passed along to the end user.
According to yet another aspect, the method of the invention reduces the labor required for producing corner posts for mounting doors to the truck box.
According to a further aspect, the method of the invention eliminates welded gussets, thereby reducing material and labor costs and providing rims having superior mechanical strength.
Other benefits and advantages of this invention will become apparent to those skilled in the art to which it pertains upon reading and understanding of the following detailed specification.
The disclosed method may take physical form in certain parts and arrangement of parts, and manufacturing steps, the embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:
FIGS. 4A1, 4A2, 4B1 and 4B2 are perspective views of two embodiments of patterned members and exploded views of backpack truck boxes formed in accordance with the method of the present invention.
Reference is now made to the drawings wherein the showings are for purposes of illustrating embodiments of the article only and not for purposes of limiting the same, and wherein like reference numerals are understood to refer to like components.
FIGS. 4A1, 4A2, 4B1, 4B2, 5A, 5B, 6A, 6B, 7 and 8 depict steps and interim product states in a method of fabricating a backpack truck box in accordance with the present invention. FIGS. 4A1, 4A2, 4B1 and 4B2 depict an initial interim product state of forming first and second patterned members 100a, 100b from sheet material, which can be sheet metal, stainless steel sheet (SST), carbon steel or alum. The patterned members 100a, 100b are pre-cut into a pattern which can be formed though a subsequent process into final panels, which are then assembled into the final backpack truck box, as will be described in detail hereinbelow. The patterned members 100a, 100b can be pre-cut using a metal saw or a laser in a computer numerical control (CNC) or by a stamping operation or other suitable operation without departing from the invention.
As also shown in FIGS. 4A1, 4A2, 4B1 and 4B2, each of the patterned members 100a, 100b are formed with a plurality of edges 110sa, 110sb, 110pa, 110pb having opposing tabs 112sa, 112sb, 112pa, 112pb formed contiguously on opposing edges of each of the first and second panels. In an exemplary embodiment of FIGS. 4A1 and 4B1, the step of forming the first and second patterned members 110a, 100b includes forming each panel 120a, 120b into a two-dimensional shape known from geometry as a “semi-truncated rectangle,” being of a generally rectangular shape but having two corners (e.g., the top-most corners) cut off or truncated. The pairs of the opposing tabs 112sa, 112sb, 112pa, 112pb are preferably rectangular in shape. Upon final assembly, these panels result in a backpack truck housing having a three-dimensional shape known from geometry as a “semi-truncated rectangular prism,” which is to say, a figure that extends linearly between the two panels 120a, 120b each having the shape of a semi-truncated rectangle. However, as shown in the alternate embodiment of FIGS. 4A2 and 4B2, these panels can also result in a solid rectangular shape, where it is appreciated that similar reference numerals refer to similar elements, in these figures and in the other figures throughout the present disclosure. It is to be further appreciated that the panels 120a, 120b could alternatively be formed from any other suitable shape without departing from the invention.
With continuing reference to FIGS. 4A1, 4A2, 4B1 and 4B2, the plurality of edges 110sa, 110sb, 110pa, 110pb of each panel 120a, 120b include first and second opposing parallel edges 110pa, 110pb and first and second opposing sloped edges 110sa, 110sb. The sloped edges 110sa, 110sb are formed along the edges of the truncated corners of the rectangle while the parallel edges 110pa, 110pb are formed along the remaining portions of the rectangular sides. The area bounded by these edges 110sa, 110sb, 110pa, 110pb and along with a top edge 114 and a bottom edge 116 defines the two-dimensional semi-truncated rectangular shape of each panel 120a, 120b, while the rectangular shaped panels are formed without sloped edges.
With ongoing reference to FIGS. 4A1, 4A2, 4B1 and 4B2, the pairs of rectangular opposing tabs 112sa, 112sb, 112pa, 112pb includes sloped edge tabs 112sa, 112sb formed respectively on opposing sloped edges 110sa, 110sb and parallel edge tabs 112pa, 112pb formed respectively on opposing parallel edges 112pa, 112pb. In the preferred embodiment, the pairs of rectangular opposing tabs 112sa, 112sb, 112pa, 112pb are mirror symmetrical with each other, as are the respective plurality of sloped and parallel edges 110sa, 110sb, 110pa, 110pb of each panel 120a, 120b.
With specific reference to FIGS. 4B1, 4B2, 5A, 5B, 6A, 6B, and 7, further steps of the present method include performing one or more bending operations upon each of the pairs of opposing tabs 112sa, 112sb, 112pa, 112pb to form first and second side portions 130sa, 130sb, 130pa, 130pb extending at a predetermined angle from each of the first and second panels 120a, 120b. The side portions 130sa, 130sb, 130pa, 130pb are generally flat portions that extend along the entire length of each of the respective edges 110sa, 110sb, 110pa, 110pb. The side portions 130sa, 130sb, 130pa, 130pb are defined by wider portions of the opposing tabs 112sa, 112sb, 112pa, 112pb, as explained hereinbelow. The steps of performing the bending operations includes forming the side portions 130pa, 130pb respectively along the first and second opposing parallel edges 110pa, 110pb and also forming the side portions 130sa, 130sb along the first and second opposing sloped edges 110sa, 110sb.
In one exemplary embodiment, the bending operations can be performed by forming dies or on a traditional press brake. However, it is to be appreciated that the bending operations can alternatively be formed by any other suitable device or process.
With continued reference to FIGS. 4B1, 4B2, 5A, 5B, 6A, 6B, and 7, the steps of performing the bending operations includes performing the bending operations upon each of the pairs of opposing tabs 112sa, 112sb, 112pa, 112pb to form perpendicular side portions 130sa, 130sb, 130pa, 130pb formed at right angles to the panels 120a, 120b. In this manner, the perpendicular side portions 130sa, 130sb, 130pa, 130pb each define a partial perimeter into an internal volume of the backpack truck box housing upon final assembly. An additional plurality of bending operations are also performed to produce perpendicularly-extending rectangular gutters 132sa, 132sb, 132pa, 132pb, formed at right angles to the to the side portions 130sa, 130sb, 130pa, 130pb and extending outwardly away therefrom. The gutters 132sa, 132sb, 132pa, 132pb are formed from portions of the opposing tabs 112sa, 112sb, 112pa, 112pb that are narrower than the side portions 130sa, 130sb, 130pa, 130pb, so that the partial perimeters resulting from each of the gutters 132sa, 132sb, 132pa, 132pb have a smaller extent than the side portions 130sa, 130sb, 130pa, 130pb. However, it is further contemplated that the gutters could be optionally substituted with a section of gasket material, without departing from the invention.
With additional reference to FIGS. 4B1, 4B2, 5A, 5B, 6A, 6B, and 7, the gutters 132sa, 132sb, 132pa, 132pb can be formed by creating a perpendicular bend along a boundary portion where the gutters 132sa, 132sb, 132pa, 132pb adjoin the 130sa, 130sb, 130pa, 130pb, and another perpendicular bend formed along the middle of the narrow portions of the opposing tabs 112sa, 112sb, 112pa, 112pb. The resulting structure of the gutters 132sa, 132sb, 132pa, 132pb are oriented so that an outer edge is angled in a direction back toward the respective outer surfaces of the first and second panels 120a, 120b. In this manner, the gutters 132sa, 132sb, 132pa, 132pb define the partial perimeters that will form the openings into the interior of the backpack truck box.
As specifically indicated in FIGS. 4A1, 4A2, 4B1 and 4B2 the bottom edge 116 of the panels 120a, 120b can be formed with a ledge 134 to provide a mounting surface. This ledge 134 can be formed in the pattern and bending operations described hereinabove. However, in an alternative embodiment, as shown in
As specifically indicated in FIGS. 4B1, 4B2, and 8, the method further includes steps of welding together the side portions 130sa, 130sb, 130pa, 130pb of the first panel 120a to respective corresponding side portions 130sa, 130sb, 130pa, 130pb of the second panel 120b to produce a welded backpack truck box housing 140. Specifically, the welding steps include welding a middle portion 142 between the side portions 130sa, 130sb, 130pa, 130pb to define a width of the backpack truck box housing. As indicated in
As also shown in
As also shown in FIGS. 4B1 and 4B2, a top portion 146 is welded onto the panels 120a, 120b of the assembled backpack truck box housing to provide an enclosure to a top surface of the backpack truck box 140. The bottom edge of the top portion 144 cooperates with the gutters 132sa, 132sb, 132pa, 132pb, 144 to define a continuous perimeter for openings 150 into the internal volume of the backpack truck box 140. Shelves 152 are optionally assembled or welded within the interior volume of the backpack truck box housing 140 Doors can then be attached to each of the partial perimeters formed by the gutters 132sa, 132sb, 132pa, 132pb, 144 for enclosing the internal volume of the backpack truck box housing 140.
Numerous embodiments have been described herein. It will be apparent to those skilled in the art that the above methods and apparatuses may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.
Having thus described the invention, it is now claimed:
