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Title:
CONTACT BODIES AND METHOD AND APPARATUS OF MAKING SAME
Document Type and Number:
WIPO Patent Application WO/2001/020241
Kind Code:
A2
Abstract:
A contact body (38) is disclosed, comprising at least two contact sheets (10, 22) having opposing surfaces and a projection (12, 14, 24, 26) extending outward from one surface of each contact sheet (10, 22), wherein the projection (12, 14, 24, 26) defines a depression on the opposite surface of the contact sheet (10, 22), a projection (12, 14) of one contact sheet (10) being disposed within a depression of an adjacent contact sheet (22) to form a projection-depression coupling (34), and the projection-depression coupling (34) being deformed to form a positive lock (36). The apparatus includes crimping devices (40, 52, 77, 79) that crimp projection-depression couplings (34) located in the interior area of the interlocked sheets (10, 22) and projection-depression couplings (34) located adjacent the side edges of the interlocked sheets (10, 22), again to form positive locks (36) by which assemblies of sheets (10, 22) are formed.

Inventors:
Aull, Richard J. (35 E. 34th Street Reading, PA, 19606, US)
Bino, Al (100 Wheatfield Road Sinking Spring, PA, 19608, US)
Krell, Timothy E. (713 Eagle Road Fleetwood, PA, 19522, US)
Rye, Palle (20 Fawn Drive Reading, PA, 19607, US)
Truex, Andrew L. (201 Wellington Road Shillington, PA, 19607, US)
Application Number:
PCT/US2000/024996
Publication Date:
March 22, 2001
Filing Date:
September 13, 2000
Export Citation:
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Assignee:
BRENTWOOD INDUSTRIES, INC. (P.O. Box 605 610 Morgantown Road Reading, PA, 19603, US)
International Classes:
F28F25/06; B01J19/32; B21D39/02; B21D39/03; B21D53/04; B29C65/00; B29C65/56; B29C65/60; F28F25/08; (IPC1-7): F28F25/08; B21D39/03; B01J19/32; B29C65/56
Foreign References:
US4395448A1983-07-26
EP0138401A21985-04-24
US3281307A1966-10-25
US3798299A1974-03-19
DE2947499B11981-06-04
DE4418651C11995-04-27
US3615274A1971-10-26
Other References:
PATENT ABSTRACTS OF JAPAN vol. 008, no. 240 (M-336), 6 November 1984 (1984-11-06) -& JP 59 120416 A (TOYOTA JIDOSHA KK), 12 July 1984 (1984-07-12)
Attorney, Agent or Firm:
Nadel, Alan S. (Akin, Gump Strauss, Hauer & Fel, L.L.P. One Commerce Square 2005 Market Square Philadelphia PA, 19103, US)
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Claims:
CLAIMS What is claimed is:
1. A contact body comprising at least two contact sheets having opposing surfaces and a projection extending outward from one surface of each contact sheet, wherein the projection defines a depression on the opposite surface of the contact sheet, a projection of one contact sheet being disposed within a depression of an adjacent contact sheet to form a projectiondepression coupling, characterized in that the projectiondepression coupling is deformed to form a positive lock.
2. The contact body according to claim 1, further characterized in that the projection of each contact sheet is in the shape of a truncated cone.
3. The contact body according to claim 1 or 2, further characterized in that the positive lock is in the form of a flattened, interlocking rivet.
4. The contact body according to any preceding claim, further characterized in that each contact sheet is a corrugated sheet having crests and valleys.
5. The contact body according to claim 4, further characterized in that the crests have peak surfaces and the valleys have trough surfaces, the peak surfaces and trough surfaces having portions that are substantially parallel to the plane of the contact sheet.
6. The contact body according to claim 4 or 5, further characterized in that the crests have peak surfaces and the valleys have trough surfaces and that a plurality of projections are located on the peak surfaces of the crests and the trough surfaces of the valleys, the projections extending in the same direction from the one surface of each contact sheet.
7. The contact body according to claim 5 or 6, further characterized in that the plurality of projections are spaced along the peak surfaces and the trough surfaces, the projections located on the peak surfaces being aligned longitudinally with the projections located on the trough surfaces.
8. The contact body according to any one of claims 5,6 and 7, further characterized in that some of the plurality of projections are edge projections on each peak surface and each trough surface adjacent side edges of each sheet, and the rest of the plurality of projections are interior projections on each peak surface and each trough surface in the interior of the sheet away from the side edges.
9. The contact body according to claim 8, further characterized in that the contact body comprises at least a first and second pair of contact sheets, the edge projections and the interior projections of the two contact sheets of each of the first and second pair form projectiondepression couplings with corresponding projections of the adjacent sheet of the pair, at least some of the projectiondepression couplings comprised of the edge projections and the interior projections of each contact sheet of the first and second pair being deformed to form positive locks between at least some of the projections of contact sheets of the pair, and further characterized in that at least some of only the edge projections of the first pair of contact sheets that form projectiondepression couplings with the edge projections of the second pair of contact sheets are deformed to form positive locks between the first and second pairs of contact sheets.
10. The contact body according to claim 9, further characterized in that the contact body further comprises a plurality of pairs of contact sheets.
11. The contact body according to claim 9 or 10, further characterized in that all of the projectiondepression couplings are deformed to form positive locks between all of the contact sheet projections of each pair, and further characterized in that all of the edge projections of each pair of contact sheets that form projectiondepression couplings with the edge projections of an adjacent pair of contact sheets are deformed to form positive locks between each adjacent pair of contact sheets.
12. A method of connecting contact sheets to form a contact body, comprising: (a) providing at least two contact sheets having opposing surfaces and a projection extending outward from one surface of each contact sheet, wherein the projection defines a depression on the opposite surface of the contact sheet; (b) positioning the projection of one of the contact sheets within the depression of an adjacent contact sheet, thereby forming a projectiondepression coupling; the method characterized by (c) deforming the projectiondepression coupling, resulting in a positive lock.
13. The method according to claim 12, further characterized in that the projection of each contact sheet is in the shape of a truncated cone.
14. The method according to claim 12 or 13, further characterized in that step (c) comprises crimping the projectiondepression coupling to form a flattened positive lock in the form of a flattened, interlocking rivet.
15. The method according to any one of claims 12,13 and 14, further characterized in that each contact sheet is a corrugated sheet having crests and valleys.
16. The method according to claim 15, further characterized in that the crests have peak surfaces and the valleys have trough surfaces, the peak surfaces and trough surfaces having portions that are substantially parallel to the plane of the contact sheet.
17. The method according to claim 15 or 16, further characterized in that a plurality of projections are located on the peak surfaces of the crests and the trough surfaces of the valleys, the projections extending in the same direction from the one surface of each contact sheet.
18. The method according to claim 16 or 17, further characterized in that the plurality of projections are spaced along the peak surfaces and the trough surfaces, the projections located on the peak surfaces being aligned longitudinally with the projections located on the trough surfaces.
19. The method according to any one of claims 16,17 or 18, further characterized in that some of the plurality of projections are edge projections on each peak surface and each trough surface adjacent side edges of each sheet, and the rest of the plurality of projections are interior projections on each peak surface and each trough surface in the interior of the sheet away from the side edges.
20. The method according to claim 19, further characterized in that the contact body comprises at least a first and second pair of contact sheets, the edge projections and the interior projections of the two contact sheets of each of the first and second pair form projectiondepression couplings with corresponding projections of the adjacent sheet of the pair, and the method is further characterized by deforming at least some of the projection depression couplings comprised of the edge projections and the interior projections to form positive locks between at least some of the contact sheet projections of the pair, and further deforming at least some of only the edge projections of the first pair of contact sheets that form projectiondepression couplings with the edge projections of the second pair of contact sheets to form positive locks between the first and second pairs of contact sheets.
21. The method according to claim 20, further characterized in that the contact body further comprises a plurality of pairs of contact sheets.
22. The method according to claim 20 or 21, further characterized by deforming all of the projectiondepression couplings of each pair of the contact sheets to form positive locks between all of the contact sheet projections of each pair, and the method further characterized by deforming all of the edge projections of each pair of contact sheets that form projectiondepression couplings with the edge projections of an adjacent pair of contact sheets to form positive locks between each adjacent pair of contact sheets.
23. An apparatus for crimping together interlocked portions of at least two sheets of deformable sheet material, the sheet material being defined by opposed side edges and having opposing surfaces, the sheet material having a plurality of projections extending outward from one surface of each sheet, wherein each projection defines a depression on the opposite surface of the sheet, a projection of one sheet being disposed within a depression of an adjacent sheet to form a projectiondepression coupling, and the sheets being characterized in that the projectiondepression coupling is deformable to form a positive lock, the apparatus characterized by a support surface for the sheets, a first crimping surface disposed adjacent one surface of the sheets and a second crimping surface disposed adjacent the opposed surface of the sheets and alignable with the first crimping surface, the first and second crimping surfaces having an open position for insertion of at least some of the projectiondepression couplings formed by aligning the sheets such that the projection of one sheet is coupled with the depression of another sheet, the first and second crimping surfaces having a crimping position that deforms the projectiondepression couplings to form a positive lock, each of the first crimping surfaces being formed on a portion of a tool having at least one of rotatable gear teeth and a jaw member relatively movable with respect to the second crimping surfaces, the second crimping surfaces being formed on at least one of rotatable gear teeth and an anvil member, the apparatus further characterized by at least two tools for crimping at least two projection depression couplings as the sheets travel past the tools.
24. The apparatus according to claim 23, further characterized in that at least some of the tools are at least two laterally disposed gears having a plurality of teeth bearing the first crimping surfaces and disposed adjacent one surface of the sheets and at least two laterally disposed gears having a plurality of teeth bearing the second crimping surfaces and disposed adjacent the opposite surface of the sheets aligned with the gear teeth bearing the first crimping surfaces.
25. The apparatus according to claim 23 or 24, further characterized in that the gears are disposed to crimp projectiondepression couplings adjacent each of the side edges of the sheets.
26. The apparatus according to any one of claims 23,24 and 25, further characterized in that at least some of the gears have teeth with beveled first and second crimping surfaces.
27. The apparatus according to any one of claims 2326, further characterized in that the gears are disposed to crimp projectiondepression couplings located in the interior of the sheets away from the side edges of the sheets.
28. The apparatus according to any one of claims 2327, further characterized in that the gears are disposed to crimp projectiondepression couplings adjacent each of the side edges of the sheets and projectiondepression couplings located in the interior of the sheets away from the side edges of the sheets.
29. The apparatus according to any one of claims 2328, further characterized in that at least some of the tools comprise jaw members bearing the first crimping surfaces and disposed adjacent one surface of the sheets, and anvil members bearing the second crimping surfaces aligned with the jaw members and disposed adjacent the opposite surface of the sheets, the jaw members and anvil members being movable with respect to each other from the open position to the crimping position.
30. The apparatus according to any one of claims 2329, further characterized in that there are at least two sets of aligned jaw members and anvil members, each set being disposed adjacent opposite side edges of the sheets.
31. The apparatus according to any one of claims 2331, further characterized in that there are a plurality of sets of aligned jaw members and anvil members disposed adjacent opposite side edges of the sheets.
32. The apparatus according to any one of claims 2331, further characterized in that the relative movement of the jaw members and the anvil members is cam actuated.
33. The apparatus according to claim 32, further characterized in that the camactuated relative movement is manually powered.
34. The apparatus according to claim 32, further characterized in that the camactuated relative movement is powered by motive power.
35. The apparatus according to any one of claims 2228, further characterized by two stations, a first station having gears disposed to crimp projection depression couplings located in the interior of the sheets away from the side edges of the sheets and gears disposed to crimp projectiondepression couplings adjacent each of the side edges of the sheets, and a second station having gears disposed to crimp projectiondepression couplings adjacent each of the side edges of the sheets.
36. The apparatus according to claim 35, further characterized by a preliminary station before the first station comprising a fixture to align the sheets and tools to crimp at least two projectiondepression couplings to form a positive lock and retain the sheets in alignment as the sheets approach the first station.
37. The apparatus according to any one of claims 2332 and 34, further characterized by two stations, a first station having gears disposed to crimp projection depression couplings located in the interior of the sheets away from the side edges of the sheets and gears disposed to crimp projectiondepression couplings adjacent each of the side edges of the sheets, and a second station having at least two sets of tools comprising jaw members bearing the first crimping surfaces and disposed adjacent one surface of the sheets, and anvil members bearing the second crimping surfaces aligned with the jaw members and disposed adjacent the opposite surface of the sheets, the jaw members and anvil members being movable with respect to each other from the open position to the crimping position, each set being disposed adjacent opposite side edges of the sheets.
38. The apparatus according to claim 37, further characterized by a preliminary station before the first station comprising an apparatus to align the sheets.
39. The apparatus according to claim 38, further characterized in that the preliminary station comprises pick and place equipment by which a first sheet is lifted and thereafter shifted onto, and in appropriate alignment with, a second sheet to form a plurality of projectiondepression couplings.
40. The apparatus according to any one of claims 2333 and 3539, further characterized in that the tools are powered manually.
41. The apparatus according to any one of claims 2332 and 3439, further characterized in that the tools are powered by motors.
42. The apparatus according to any one of claims 2332,3439 and 41, further characterized in that each of the stations has an automated operation.
Description:
Published: -with international search report (88) Date of publication of the international search report : 18 October 2001 For two-letter codes and other abbreviations, refer to the"Guid- ance Notes on Codes and Xbbreviations"appearing at the begin- ning of each regular issue of the PCT Gazette.