ELEVATOR DOOR SILL CROSS-REFERENCE TO RELATED APPLICATIONS

[oooi] This International PCT Application claims priority to, and hereby incorporates by reference in its entirety, Chinese Patent Application No. 200920300310.X, which was filed on January 19, 2009.

BACKGROUND

[0002] Elevator systems include doors on the elevator car and doors at the landing where a passenger can enter or exit the elevator car. At each landing a sill provides a finished surface that at least partially covers a gap between the landing floor and the inside of the elevator car.

[0003] Conventional techniques for making elevator sills include machining a solid metal rod to cut away a groove that is useful for guiding movement of an elevator door and to otherwise provide the desired profile of the sill. One disadvantage with the conventional technique is that it requires additional material that is machined away. In some examples, the sill also has excess weight, which can make it more difficult to handle and manipulate during the installation process.

SUMMARY

[0004] An exemplary sill for use in an elevator system includes a sill plate that is a single piece of metal. The sill plate has a first portion in a first plane and a second portion adjacent to the first portion. The second portion is bent into a second plane that intersects the first plane. A third portion is adjacent to the second portion. The third portion is bent at least partially into a third plane that intersects the second plane.

A fourth portion is adjacent to the third portion. The fourth portion is bent into a fourth plane that intersects the third plane and intersects the first plane. A fifth portion is adjacent to the fourth portion. The fifth portion is bent into the first plane.

The second, third and fourth portions collectively establish a groove that is configured to receive a portion of an elevator system door. A base portion is provided in a plane parallel to the first plane. Connector portions near opposite ends of the base portion protrude from the base portion in a direction toward the first plane of the sill plate. At least one of the connector portions is connected to a selected portion of the sill plate near an end of the sill plate. 60,469-486 PCT; PA-OO 12281 -WO

[0005] An exemplary method of forming a sill for use in an elevator system includes forming a sill plate from a single piece of metal. The piece of metal is bent a first time to establish a first portion in a first plane and a second portion in a second plane and adjacent the first portion. The piece of metal is bent a second time near an end of the second portion to establish a third portion adjacent the second portion. The third portion is at least partially in a third plane that intersects the second plane. The piece of metal is bent a third time near an end of the third portion to establish a fourth portion adjacent to the third portion and in a fourth plane that intersects the third plane. The fourth plane also intersects the first plane. The piece of metal is bent a fourth time near an end of the fourth portion to establish a fifth portion adjacent the fourth portion. The fifth portion is also in the first plane. The second, third and fourth portions collectively establish a groove configured to receive a portion of an elevator system door. A supporting channel is formed to establish a base portion and connector portions near opposite ends of the channel member that protrude from the base portion. The supporting channel member is positioned adjacent the sill plate and at least one of the connector portions is connected to a selected portion of the sill plate.

[0006] The various features and advantages of disclosed examples will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 schematically illustrates selected portions of an elevator system including a sill member designed according to an embodiment of this invention.

[0008] Figures 2A - 2E schematically illustrate an example process of making a sill designed according to an embodiment of this invention.

[0009] Figure 3 is a cross-sectional illustration showing one example sill configuration.

[00010] Figure 4 is a cross-sectional illustration showing another example sill configuration.

[00011] Figure 5 is a cross-sectional illustration showing another example sill configuration. 60,469-486 PCT; PA-OO 12281 -WO

[00012] Figure 6 is a cross-sectional illustration showing another example sill configuration.

[oooi3] Figures 7 A - 7H schematically illustrate another example process of making a sill designed according to an embodiment of this invention.

DETAILED DESCRIPTION

[oooi4] Figure 1 schematically shows selected portions of an elevator system 20. An elevator lobby 22 provides access to a plurality of elevator cars through elevator doors 24. Each doorway includes a sill 30 at the threshold of the access point where a passenger can move between the lobby 22 and an elevator car.

[oooi5] The sills 30 are formed in a unique manner that reduces cost by minimizing the amount of material required and enhances other economies associated with providing and installing sill members in an elevator system.

[00016] Figures 2 A - 2E schematically illustrate a sequence of steps for making an elevator sill designed according to an embodiment of this invention.

Figure 2A illustrates a single piece of metal material that is formed into a sill plate 32.

In one example, the single piece of metal comprises a generally planar and generally rectangular sheet of stainless steel.

[oooi7] Figure 2B illustrates a first bending step in which the single piece of material has been bent at 34 to establish a first portion 36 that is in a first plane on one side of the bend 34. A second portion 38 is on another side of the bend 34. The second portion 38 lies in a second plane that intersects with the first plane. In this example, the second portion 38 is generally perpendicular to the first portion 36.

[00018] Figure 2C schematically illustrates a next step in the example process. A second bend 40 establishes one end of the second portion 38 and establishes a third portion 42 of the sill plate 32. The third portion 42 lies at least partially in a plane that intersects the plane of the second portion 38. In this example, the plane of the third portion 42 is parallel with the plane of the first portion 36. The second portion 38 is perpendicularly aligned with the first portion 36 and the third portion 42. [oooi9] Figure 2D illustrates a next step in the example sequence for forming the sill plate 32. Another bend at 44 establishes a fourth portion 46 adjacent the third portion 42. The fourth portion 46 is in a plane that intersects the plane of the third portion 42. In this example, the fourth portion 46 is in a plane that also intersects the 60,469-486 PCT; PA-OO 12281 -WO

plane of the first portion 36. As can be appreciated from the drawing, the fourth portion 46 is generally parallel with the second portion 38 in this example.

[00020] Figure 2E schematically illustrates another stage in the example process. Another bend 48 in the single piece of metal establishes a fifth portion 50 adjacent the fourth portion 46. In this example, the fifth portion 50 is in the same plane as the first portion 36. The plane of the fifth portion 50 intersects with the plane of the fourth portion 46.

[00021] The second portion 38, third portion 42 and fourth portion 46 collectively establish a groove 52 that is configured to receive a portion 24' (shown in phantom in Figure 3) of an elevator system door 24.

[00022] As also shown in Figure 2E, a supporting channel member 60 is formed from a single piece of sheet metal material. A base portion 62 is in a plane that is generally parallel to the plane of the first portion 36 and the fifth portion 50. Connector portions 64 and 66 protrude from the base portion 62 in a direction toward the sill plate 32. The connector portions 64 and 66 are formed in one example by bending the sheet metal material of the supporting channel member 60 at bends 63, 65. The connector portions 64 and 66 are configured to be connected to the sill plate 32 near ends of the sill plate.

[00023] Figure 3 schematically shows one example completed sill. In this example the sill plate 32 includes a connecting flange portion 70 that is formed by bending a portion of the piece of metal of the sill plate 32 adjacent to fifth portion 50 at a bend 54. The connector portion 66 is received against the connecting flange portion 70 and secured to it. The connector portion 64 in this example includes two sections 64A, 64B connected at a bend 67. The first 64A of the sections is perpendicular to the base 62 while the second 64B of the sections is generally parallel to the base 62. As can be appreciated from the illustration, the second 64B of the sections of the connector portion 64 is received against the first portion 36 of the sill plate 32 and secured to it.

[00024] In one example, the supporting channel member 60 is welded to the sill plate 32 so that the two are secured together. A generally rectangular, closed cross- section is established when the supporting channel member 60 is secured to the sill plate 32. This rectangular, closed cross-section provides rigidity to the sill so that it is strong enough to perform as an elevator sill is expected to perform. At the same time, the amount of material required is reduced, which provides material cost savings. 60,469-486 PCT; PA-OO 12281 -WO

Additionally, the sill 30 has a lighter weight compared to conventional sills, which makes it easier to transport and manipulate for purposes of installing the sill in an elevator system.

[00025] Figure 4 shows another example sill arrangement. In this sill 30, the sill plate 32 includes a second groove 52. The single piece of material used to form the sill plate 32 in this example includes a sixth portion 72, a seventh portion 74, an eighth portion 76 and a ninth portion 78 respectively formed by bends 56, 57, 58, and 59. Each of those portions are established by bending the single piece of material into the configuration shown in Figure 4. Such a sill accommodates an elevator door arrangement that has multiple door panels, for example.

[00026] Another difference between the example of Figure 4 and the example shown in Figure 3 is that the connector portion 64 includes only one section protruding from the base 62. Another connecting flange portion 80 is established adjacent the first portion 36 by bending the single piece of metal used to form the sill plate 32 at bend 28. The connection between the connector portions 64 and 66 and the connecting flanges 80 and 70 are established in one example by welding.

[00027] Another example arrangement is shown in Figure 5. This example is similar to the example of Figure 4 with the exception of how the sill plate 32 is secured to the supporting channel member 60. In this example, fasteners 82 are used to secure the two pieces together. One example includes rivets as the fasteners 82. Another example includes screws as the fasteners 82. Still another example includes bolts as the fasteners 82.

[00028] Figure 6 shows another example that includes features of the Figure 3 example (e.g., a connector portion 64 formed of two sections 64A, 64B) and features of the Figure 4 example (e.g., two grooves 52). In the example arrangement of Figure 6, however, the third portion 42 and the seventh portion 74 are at least partially curved rather than being generally planar across their entire length. The curved profile of the third portion 42 and the seventh portion 74 are established by bending the single piece of material used to form the sill plate 32 into a curved shape, thereby eliminating sharp bends 40, 44, 57, and 58, in one example.

[00029] The curved profile of the bottom of the grooves 52 in the example of Figure 6 can be useful for reducing abrasion between the portion 24' of an elevator door 24 and the inner walls of the grooves 52 during opening and closing movements of the elevator doors 24. 60,469-486 PCT; PA-OO 12281 -WO

[00030] Referring to Figures 7A - 7H, another example method is schematically shown performing another embodiment of a sill 30 designed according to an embodiment of this invention. The sill plate 32 of Figures 7A - 7E is essentially the same as that of Figures 2A - 2E, with the exception of the length of material as can be appreciated by comparing those drawings.

[00031] Figure 7F shows another step in the bending process. In this step, a bend 100 establishes a connector portion 102 adjacent the fifth portion 50.

[00032] Figure 7G shows another step in which a bend 104 establishes another connector portion 106 near one end of the piece of material 32. [00033] Figure 7H shows another step in which a bend 108 between the bend

100 and 104 establishes a base portion 110 between the connection portions 102 and 106. The base portion 110 is parallel with the first portion 36 and the fifth portion 50. The connector portions 102 and 106 protrude from the base portion 110 toward the portions of the sill plate that are in the first plane (e.g., the first portion 36 and the fifth portion 50). At the bend 100, the connector portion 102 is connected to the fifth portion 50. In this example, the connector portion 106 is connected to the first portion 36 by welding or another connection technique such as one of those from the embodiments described above.

[00034] The various features of the disclosed examples may be combined into other variations not specifically illustrated to meet the needs of a particular situation. Each example demonstrates how a sill 30 can be formed of a sill plate 32 and a supporting channel member 60 from a monolithic, single piece of metal or from two pieces of metal. Bending metal sheets into the illustrated configurations and securing them together yields an economical and stable sill for use in an elevator system. [00035] The preceding description is exemplary rather than limiting in nature.

Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this invention. The scope of legal protection given to this invention can only be determined by studying the following claims.