Patent Application
20080149647
Many waste containers are constructed using heavy and bulky materials. For example, many waste containers for commercial and/or outdoor use employ thick and heavy construction materials for sidewalls, doors, and other container components. Although often providing the advantage of container strength, such container designs typically use material inefficiently, resulting in a significant increase in container weight, manufacturing and shipping costs, and a more expensive waste container.
Some waste container designs include a door pivotably connected to a housing for access to an interior of the waste container. Such waste containers often have an expensive hinge assembly capable of supporting the weight of a conventional door and the loads experienced by the door in use. The container normally has an inefficient structural design matching that of the hinge to which it is connected in order to insure a reasonably long door life. Particularly in light of the ever-increasing raw material costs of metal, plastic, and other waste container construction materials, a demand exists for waste containers that have a more efficient design, are easier to manufacture, and/or can be manufactured at reduced costs without sacrificing container durability.
Some embodiments of the present invention provide a waste container, comprising a housing comprising a wall defining an exterior surface of the waste container and having a surface area, the wall having a first plurality of apertures extending therethrough, the first plurality of apertures occupying at least 39% of the surface area of the wall; a hinge pin coupled to the housing; a thrust bearing coupled to the housing; and a door pivotably coupled to the housing by the hinge pin, supported by the thrust bearing, and defining another exterior surface of the waste container and having a surface area, the door pivotable between opened and closed positions with respect to the housing; the thrust bearing and the hinge pin carrying a reduced load from the door by virtue of a second plurality of apertures extending through the door and occupying at least 39% of the surface area of the door.
In some embodiments, a method of assembling a waste container is provided, and comprises coupling a thrust bearing to one of a housing and a door of the waste container; positioning the door adjacent an opening of the housing; coupling a hinge pin to the thrust bearing; coupling the door to the housing via the hinge pin, the door having an exterior surface area; supporting a load from the door upon the hinge pin and thrust bearing, the load defined in part by a plurality of apertures extending through the door, the plurality of apertures distributed across and occupying at least 39% of the exterior surface area of the door; and rotating the door between opened and closed positions with respect to the housing.
Some embodiments of the present invention provide a waste container comprising: a door comprising a first body defining an exterior of the door and partially defining an exterior of the waste container; a housing comprising a second body defining an exterior of the housing and partially defining the exterior of the waste container; a hinge pin extending and coupled to a first plate on the door and a second plate on the housing, the door pivotable about a rotational axis of the hinge pin between opened and closed positions with respect to the housing; a first reinforcing plate coupled to the first plate on the door; a second reinforcing plate coupled to the second plate on the housing; and a thrust bearing coupled to the hinge pin, wherein the door includes a substantially rigid sheet defining the exterior of the door and through which a plurality of apertures are defined, the apertures occupying at least 39% of the exterior of the door.
Further aspects of the present invention, together with the organization and operation thereof, will become apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
A waste container according to an embodiment of the present invention is illustrated in
As best shown in
With reference back to
In some embodiments, the wall 30 can be made from perforated steel, perforated aluminum, or any other suitably rigid material. The diameter of the illustrated housing 14 can be such that the vertical portion 26 of the base 12 fits inside the housing 14. In other embodiments, the housing 14 can fit within the vertical portion 26 of the base 12, the base 12 can abut the housing 14 and be connected thereto in any suitable manner, the base 12 can be snap-fit to the housing 14 or can be connected thereto by any type of inter-engaging elements on the housing 14 and base 12, or as mentioned earlier, the base 12 can be formed integrally with the housing 14. In some embodiments, the vertical portion 26 of the base 12 is be secured to the housing 14 by welding or brazing, by any number of screws, rivets, pins, clamps, or other fasteners, by inter-engaging elements on the base 12 and wall 30 as mentioned above, by a press-fit connection between the base 12 and wall 30, or any other suitable manner of attachment. In other embodiments, other portions of the base 12 can be attached to the wall 30 depending at least in part upon the shape of the base 12.
As best shown in FIGS. 2 and 4-6, the upper support 15 of the illustrated embodiment includes a vertical portion 42 and a substantially horizontal portion 44 extending from the vertical portion toward the middle of the upper support 15. The upper support 15 helps to stiffen the housing 14, and can include cross members similar to the base 12. In some embodiments, the upper support 15 can be stiffened by elements or structure other than cross members, such as by connecting a grid of wires or rods within the upper support 15, connecting a solid or perforated bottom wall within the upper support 15, or by connecting a rigid mesh wall within the upper support 15. In the event that any of these stiffening methods is used, they can still be shaped to provide an aperture through which waste can be placed into the waste container 10.
In other embodiments, the housing 14 can fit within the vertical portion 42 of the upper support 15, the upper support 15 can abut the housing 14 and be connected thereto in any suitable manner, the upper support 15 can be snap-fit to the housing 14 or can be connected thereto by any type of inter-engaging elements on the housing 14 and upper support 15, or the upper support 15 can be formed integrally with the housing 14. In some embodiments, the vertical portion 42 of the upper support 15 can be secured to the housing 14 by welding or brazing, by any number of screws, rivets, pins, clamps, or other fasteners, by inter-engaging elements on the upper support 15 and wall 30, by a press-fit connection between the upper support 15 and wall 30, or any other suitable manner of attachment. In other embodiments, other portions of the upper support 15 can be attached to the wall 30 depending at least in part upon the shape of the upper support 15. The upper support 15 illustrated in
The door 16 of the illustrated embodiment is defined at least in part by a curved wall 50, although other shapes of the door 16 are possible, and fall within the spirit and scope of the present invention. The door 16 illustrated in
The illustrated door 16 also has an upper brace 54, a lower brace 56, and vertical braces 57. When the waste container 10 is assembled, the curved shape of the wall 50 in the illustrated embodiment completes the substantially cylindrical shape of the housing 14. In some embodiments, the wall 50 is made from steel having a thickness of at least 1/16″ and no greater than 3/16″. The wall 50 can include apertures 35 to provide airflow into and out of the waste container 10 and to decrease the weight of the door 16. The apertures 35 can have any shape, including round, oval, polygonal, or any other desired shape. The shape and/or size of the apertures 35 can be consistent across the wall 50, or alternatively the shape and/or size of the apertures 35 can vary across the wall 50. The apertures 35 can have generally any size, but an average size no smaller than about 0.463 inches and no greater than about 0.502 inches in largest dimension (e.g., diameter for round apertures 35, length for elongated apertures 35, and the like) is desired in many applications. In other applications, the apertures 35 have an average size no greater than about 0.75 inches and no less than about 0.25 inches to provide good performance results. The apertures 35 can be located anywhere on the wall 50, and can be arranged in patterns or in random and patternless locations across the wall 50. By way of example only, the apertures 35 can be located only in certain regions of the wall 50, such as only in the center portion of the wall 50 or only at the top, bottom, and/or sides of the wall 50. In other embodiments, the apertures 35 can cover substantially the entire wall 50. In the illustrated embodiment, the wall 50 has apertures 35 extending substantially across all surfaces of the wall 50, although only a few apertures 35 are shown for clarity.
The weight of the door 16 and the forces generated by the door 16 in its various positions with respect to the housing 14 have a significant impact upon the characteristics and performance of the door hinge (described in greater detail below) and the housing 14. The inventors have discovered a relationship between the construction of the door 16 and that of the hinge and/or housing 14 that permits the use of a relatively lightweight door hinge and a reduction in the strength and material requirements of the housing 14 while still providing a strong and durable waste container 10. In some embodiments, the wall 50 can be made from perforated steel, perforated aluminum, or any other suitably rigid material. The inventors have also discovered that in some embodiments, apertures 35 covering at least about 39% of the surface area of the wall 50 (and in some embodiments having a material thickness and/or the dimensions described above) can be used for good performance results.
The shape of the door 16 can significantly impact the relationship between the door 16, the hinge (described below), and the housing 14. In the illustrated embodiment, a curved wall 50 of the door 16 provides a reduced torque on the hinge portions 28, 46, and therefore a reduced torque upon the housing 14. By virtue of the apertures and resulting reduced weight of the door 16, still lower torque is exerted upon the hinge portions 28, 46. Other door shapes can be utilized to provide a smaller moment arm with respect to the hinge portions 28, 46, including non-planar door shapes having the same surface area as planar door shapes.
In some embodiments, the door 16 is reinforced in order to maintain a desired relationship between material thickness, door weight, and aperture amount described above. For example, the door 16 in the illustrated embodiment has substantially horizontal upper and lower braces 54, 56 that extend inward from the wall 50 toward the middle of the waste container 10. The upper and lower braces 54, 56 and the vertical braces 57 of the illustrated door 16 help stiffen and strengthen the door 16. In some embodiments, different styles and quantities of door reinforcing elements can be used, and can take a number of different forms. For example, the wall 50 of the door 16 can also or instead be provided with one or more gussets, reinforcing brackets, braces, and the like. Such reinforcing elements can be connected to the top and bottom of the door 16 to provide reinforcement for the hinge portions 28, 46.
As best shown in
The door 16 of the illustrated waste container 10 is pivotally coupled to the waste container 10 by the lower hinge portion 28 and the upper hinge portion 46. In the illustrated embodiment of
As best shown in
With continued reference to the illustrated embodiment of the waste container 10, the hinge pin 80 is threaded into the nut 82 adjacent the horizontal portion 44 of the upper support 15. The hinge pin 80 is threaded into the nut 82 such that the nut 82 can transfer substantially all of the weight of the door 16 to the horizontal portion 44. The upper support 15 includes gussets 86 coupled between the vertical portion 42 and the horizontal portion 44 to help reinforce and stiffen the upper support 15. The upper support 15 can also or instead be reinforced with other reinforcing plates, such as plates similar to the plates 58 of the door 16 discussed above. For example, such plates could be positioned on the vertical portion 42 and/or the horizontal portion 44 to help reinforce and stiffen the upper support 15.
The door 16 in the illustrated embodiment can be raised and lowered with respect to the rest of the waste container 10 by threading the hinge pin 80 into or out of the nut 82. The door 16 can be raised far enough to remove a significant amount, most, or substantially all of the weight of the door 16 from the lower hinge portion 28. A gap 88 exists between the plate 58 and the horizontal portion 44 of the upper support 15 to permit the door 16 to be raised as described. Depending on the construction of the hinge portions 28, 46, the hinge pins 72, 80 can be replaced with other elements providing different manners of adjusting the height of the door 16. For example, a pin can have multiple circumferential grooves spaced along a length of the pin, any one of which can receive a C-clip for supporting at least part of the weight of the door 16. As another example, a pin having multiple holes spaced along a length of the pin can be employed, wherein a cotter pin can be inserted in any one of the holes for supporting at least part of the weight of the door 16. Still other manners of door height adjustment are possible, and fall within the spirit and scope of the present invention.
As described above with reference to the illustrated embodiment, the lower hinge portion 28 has a hinge pin 72 extending into a nut 28 on the base 12, and the upper hinge portion 46 has a hinge pin 80 extending through aperture 60 in the upper support 15. It should be noted that other pin and aperture arrangements can be employed to perform the same or similar function. For example, the nut 28 can be replaced with a pin fixed to the base 12 for engagement with the door 16, and/or the upper support 15 can have a pin fixed thereto for engagement with the door 16. In these embodiments, the door 16 can include hinge portions configured to receive the pins fixed to the base 12 and the upper support 15 to rotatably support the door 16 with respect to the housing 14. Also, in some embodiments, the door 16 can be coupled to the waste container 10 with a single long hinge pin extending between the hinge portions 28, 46 to rotatably support the door 16 on the housing 14. It should also be noted that still other relationships between the door 16, hinge pins, base 12, and upper support 15 are possible, and fall within the spirit and scope of the present invention.
The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention as set forth in the appended claims.
