Multi-access base

Abstract

The present invention relates to a base (41) for providing support to a structure to which the base is attached, wherein the base comprises four-sides and each side comprises a pair of openings (43a, 44a) for receiving the forks of a forklift or a pedestrian truck, and wherein the openings are accessible in the same plane.

Description

[0001] Multi-Access Base

[0002] Technical Field of the Invention

[0003] The present invention relates to a base for providing support to a structure, to an assembly comprising the base, to a method of producing the base and to a component of the base.

[0004] Background to the Invention

[0005] Additive manufacturing (AM) generally relates to the process of manufacturing 3D objects by building up layers of a material or materials. Conventionally, the materials may be supplied to additive manufacturing machines in the form of powders (e.g. metal powders). For small scale manufacturing processes, the powders may be supplied in containers (e.g. plastic jars). For larger scale processes, hoppers have been designed for transporting large amounts of powder and delivery to additive manufacturing machines. Such hoppers typically comprise an upper cylindrical section and a lower conical section comprising a mouth through which AM powder is discharged in use. Three elongate V-section support legs are fixed to and are spaced circumferentially around the hopper. The support legs are mounted onto an industry standard pallet system so that the hopper can be transported using a fork-lift truck. The industry standard pallet system is formed from metal or a metal alloy. However, due to their construction, these pallet systems are only accessible from the front and rear which inhibits transport and movement of the hopper within an AM facility. This is especially problematic in smaller AM facilities or in facilities where multiple hoppers are being stored. Another drawback is that the forks of the forklift are not fully enclosed by the pallet in use and so there is an increased risk of the hopper being dropped, e.g. in the event of a collision or as a result of driver error.

[0006] It is an object of embodiments of the invention to provide an improved base to which a container or structure may be mounted that facilitates transport of the container or structure in use.

[0007] It is another object of embodiments of the invention to provide an improved base which enables a mounted container or structure to be transported reliably and safely.

[0008] It is a further object of embodiments of the invention to provide a base that that can be assembled easily and quickly.

[0009] Summary of the Invention

[0010] According to a first aspect of the invention there is provided a base for providing support to a structure to which the base is attached, wherein the base comprises four- sides and each side comprises a pair of openings for receiving the forks of a forklift or a pedestrian truck, and wherein the openings are accessible in the same plane.

[0011] The base may comprise four interlinking tubular members. The tubular members may comprise a rectangular cross-section. In some embodiments the tubular members may comprise a square cross-section. The four interlinking members may be substantially identical.

[0012] The tubular members may be arranged to define a hash-shaped frame. The hashshaped frame may comprise a central open area. Advantageously, this reduces the overall weight of the base. Each tubular member may comprise a first end having a first opening and a second end having a second opening.

[0013] Each tubular member may comprise a channel that extends in a direction perpendicular to the long axis of the tubular member. In some embodiments each tubular member comprises at least two channels. The channels may be substantially the same shape and size.

[0014] Each tubular member may comprise a first channel positioned inward from the first opening and a second channel positioned inward from the second opening. The first channel of one tubular member may be arranged to face the second channel of another tubular member positioned transversely thereto. The first channel may be a u- shaped channel. The second channel may be a n-shaped channel. The channels may be complementary in shape and size such that the u-shaped channel can receive the n- shaped channel for example.

[0015] The tubular members may be arranged so that the base comprises a planar top surface.

[0016] The tubular members may be arranged so that the underside of the base is flat. Advantageously, this allows the base to be lifted by a pallet truck from below the base.

[0017] The tubular members may be formed from a metal or metal alloy. In some embodiments the tubular members may be formed steel such as stainless steel.

[0018] The tubular members may be welded together. According to a second aspect of the invention there is provided an assembly comprising a container, a base and a plurality of support legs attached to the container and the base, wherein the base is the base according to the first aspect of the invention.

[0019] The assembly according to the second aspect of the invention comprises the base of the first aspect of the invention. Therefore, the assembly according to the second aspect of the invention may, as appropriate, comprises any or all of the features described in relation to the first aspect of the invention.

[0020] The assembly may comprise at least four support legs. The base may be attached to each support leg at a lower end thereof. The support legs may be attached to the base at an intersection defined by two transversely arranged tubular members.

[0021] The container, the support legs and the base may be formed from a metal or metal alloy, e.g., from stainless steel. The container, the support legs and the base may be welded together.

[0022] According to a third aspect of the invention there is provided a method of assembling a base for providing support to a structure, the method comprising the steps of: a) providing four tubular members having first and second openings for receiving the forks of a forklift or a pedestrian truck; and b) arranging the tubular members to provide a hash-shaped frame, wherein the hash-shaped frame comprises four sides and the openings are accessible in the same plane. The method according to the third aspect of the invention relates to a method of producing a base according to the first aspect of the invention. Therefore, the method according to the third aspect of the invention may, as appropriate, comprise any or all of the features of the base described in relation to the first aspect of the invention.

[0023] Each tubular member may comprise a first channel located inward from the first opening and a second channel located inward from the second opening and the method may comprise the step of arranging the tubular members so that the first channel of one tubular member faces the second channel of another tubular member positioned transversely thereto. For example, the n-shaped channel of one tubular member may face and engage with the u-shaped channel of another tubular member.

[0024] In some embodiments the method may comprise the step of securing the tubular members together to provide a rigid hash-shaped frame. The tubular members may be formed from a metal or metal alloy. The tubular members may be welded together.

[0025] The base may be subjected to a mechanical and / or chemical treatment to provide a smooth planar top surface. For example, the smooth planar top surface may be obtained by polishing.

[0026] According to a fourth aspect of the invention there is provided a tubular member comprising a first end having a first opening and a second end having a second opening, wherein a first channel is provided inward from the first opening and a second channel is provided inward from the second opening, and wherein the channels are arranged perpendicular to the long axis of the tubular member.

[0027] The tubular member according to the fourth aspect of the invention is for use in the base of the first aspect of the invention and in the method of the third aspect of the invention. Therefore, the tubular member of the fourth aspect of the invention may, as appropriate, include any or all of the features described in relation to the first and third aspects of the invention.

[0028] The first channel may comprise a u-shaped channel and the second channel may comprise a n-shaped channel.

[0029] Detailed Description of the Invention

[0030] In order that the invention may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:

[0031] Figure 1 is a front perspective view of the assembly for transporting and storing AM powder comprising a base;

[0032] Figure 2 is a rear perspective view of the assembly shown in Figure 1 ;

[0033] Figure 3 is a front view of the assembly shown in Figure 1 ;

[0034] Figure 4 is a top view of the assembly shown in Figure 1 ;

[0035] Figure 5 is a bottom view of the assembly shown in Figure 1 ;

[0036] Figure 6 is a perspective view of a partially assembled base separate from the assembly shown in Figure 1;

[0037] Figure 7 is a perspective view of a fully assembled base shown in Figure 1 ;

[0038] Figure 8 is an exploded perspective view of a hollow upright section comprising a top cap and a bottom cap; Figure 9 is a cross-sectional view of the upright hollow section comprising a top cap and a bottom cap; and

[0039] Figure 10 is a front perspective view of a hollow upright section.

[0040] Referring to the drawings, Figures 1-3 show an assembly 100 which comprises a container 10. The container 10 may include powder, e.g. metal powder, for an additive manufacturing process.

[0041] The container 10 comprises an inverted square pyramidal portion 11 having tapering side walls 12 that lead to an outlet 13. The container also comprises a body portion 14. The body portion 14 is integral with the square pyramidal portion 11 and is cuboidal in shape. The body portion 14 comprises four side walls 15 that extend upwardly above the inverted square pyramidal portion 11. The side walls 15 are joined together at their edges to define four upwardly extending corners. The container 10 comprises a bevelled or chamfered edge 16 that extends between the sidewalls 15 and a top plate 17.

[0042] The top plate 17 comprises a circular opening which allows powder to be admitted into the container 10. A removable lid 18 is provided for closing the circular opening. The lid 18 comprises an annular groove on an underside thereof for receiving a seal. The seal may be made from food-grade silicone or a synthetic rubber such as ethylene propylene diene terpolymer (EPDM). In use, the lid 18 seals against a first coupling member (not shown) mounted within the circular opening. In this embodiment the first coupling member is a ferrule. The first coupling member comprises an annular collar portion with an annular connection flange at one end. The annular connection flange may comprise an annular indentation on an upper surface thereof for receiving a seal, e.g. an O-ring. The lid 18 is clamped to the first coupling member using a clamp 19. The clamp 19 comprises a pair of curved arms 20 which each define a recess for receiving respective flanges of the coupling member and the lid 18. In this embodiment, the arms 20 each have a first end 21 and a second end 22. The arms 20 are connected at their first ends 21 which allows the arms 20 to pivotally move relative to one another. The clamp 19 also comprises a catch 23 for releasably connecting the arms 20 at their second ends 22. The catch 23 may have a mechanism for adjustably drawing the second ends 22 of the clamp arms 20 towards each other.

[0043] The lid 18 is provided with a plurality of apertures with fittings that allow valves, gauges, and other ancillaries to be connected to the lid 18 as appropriate and communicate with the internal space within the container 10. In this embodiment the lid 18 is provided with a first valve arrangement 24 for controlling the flow of powder into the container 10 through an aperture in the lid 18. In particular, the first valve arrangement 24 is in the form of a butterfly valve. However, it will be appreciated that the first valve arrangement 24 can comprise any suitable valve type for controlling the flow of powder into the container 10. As best shown in Figure 4, the butterfly valve 24 comprises a first handle 25 which, in use, may be used to open and / or close the butterfly valve 24. The lid 18 also comprises a gas inlet 26a and a gas outlet 26b to which respective ball valves 27a, 27b are connected. The gas inlet 26a and gas outlet 26b allow the atmosphere inside the container 10 to be controlled. In this respect, the gas inlet 26a can be used to admit a gas into the container 10, whilst the outlet 26b can be used as a balancing line. Accordingly, the gas inlet 26a and gas outlet 26b may be used to control a pressure level inside the container 10. For example, it may be desirable to increase the pressure within the container 10 to aid flow of the powder from the outlet 13. The gas may in some instances comprise air or a specific type of gas that is capable of preserving the condition of the powder in the container 10. For example, the gas may comprise an inert gas (e.g. argon, nitrogen, etc.) which may suitably inhibit oxidation or other deterioration of the powder within the container. The lid 18 is additionally provided with a pressure gauge 28 and a pressure release valve 29 which allows the pressure within the container 10 to be monitored and controlled respectively.

[0044] The outlet 13 of the container 10 is adapted for connection to a second valve arrangement 30 which is configured to control the flow of powder out of the container 10 into a component of an additive manufacturing process, e.g. into an additive manufacturing machine. The second valve arrangement 30 may comprise a butterfly valve. A second coupling member in the form of a ferrule is mounted within the outlet 13 so that the outlet can be coupled to the second valve arrangement 30. The second coupling member comprises an annular connection flange. This annular connection flange comprises an annular indentation on an outer surface thereof for receiving a seal. The second coupling member is hollow and defines an outlet port through which flowable material can exit the container 10. The annular connection flange of the second coupling member is secured against a corresponding flange of the second valve arrangement 30 using a second clamp 31. The opposite end of the second valve arrangement 30 comprises a further flange so that it may be coupled to an additive manufacturing machine for example, or to another component of an additive manufacturing process. Clamps sold under the trade mark TRI-CLAMP are also suitable for securing the annular connection flange of the second coupling member to the corresponding flange of the second valve arrangement 30. The assembly 100 comprises four elongate, upright hollow sections 32 or ‘legs’ which, in use, support the container 10. The legs 32 have a generally square crosssection with curved comers and house the upwardly extending comers of the body portion 14. As best shown in Figures 8 and 10, each leg 32 comprises a cut-out 33 for receiving the comers of the body portion 14. The cut-out 33 comprises a sloped upper portion 33a for receiving the bevelled or chamfered edge 16 and a curved lower portion 33b for receiving the container 10 at the junction between the body portion 14 and the inverted square pyramidal portion 11. The body portion 14, the inverted square pyramidal portion 11 and the bevelled or chamfered edge 16 are welded to the legs 32 to secure the container 10 therein. So, part of the internal volume of the container 10 extends into the interior of the legs 32.

[0045] The legs 32 are arranged to extend above the first valve arrangement 24, the gas inlet 26, the pressure gauge 28, and the pressure release valve 29 (hereafter collectively referred to as “ancillaries”). This helps protect the ancillaries in use. The assembly 100 also comprises a plurality of gussets 34 which extend between an upper surface of the container 10 and an exterior surface of the legs 32. Each leg 32 is connected to two gussets 34. The gussets 34 are arranged at right angles to each other, and the base of each gusset 34 is tapered to accommodate the bevelled or chamfered edge 16. The gussets 34 serve to strengthen the connection between the legs 32 and the container 10.

[0046] Each leg 32 comprises a top cap 35. The top cap 35 is welded to the leg 32 and comprises an aperture 36 and a hex nut 37. The hex nut 31 is welded to the underside of the top cap 35 and, in use, is housed within the leg 32. The aperture 36 and hex nut 37 are dimensioned and arranged to receive a lifting bolt (not shown) so that the assembly 100 can be lifted by a crane or other lifting device. The lifting bolt comprises a threaded tail portion which threadably engages the hex nut 37 and a looped portion for engaging a component of the crane or other lifting device. Each leg 32 also comprises a bottom cap 38 which in use serves as a skid plate to protect and reinforce the bottom of the leg 32. The bottom cap 38 is formed from nylon and comprises a central circular opening 39. Each comer of the bottom cap 38 also comprises a frustoconical opening 40 which enables the bottom cap 38 to be secured to the leg 32 using suitable fasteners (not shown).

[0047] The assembly 100 comprises a base 41 which serves to the strengthen and increase the overall rigidity of the assembly 100. The base 41 is formed from four substantially identical tubular members 42 having a rectangular cross-section which interlink and are connected together to form a hash-shaped frame. Each tubular member 42 comprises a first end 43 having a first rectangular opening 43 a and a second opposite end 44 having a second rectangular opening 44a. The first and second rectangular openings 43a, 44a serve as access points for the forks of a forklift or pallet truck which extend through the tubular members 42 in use. The first and second ends 43, 44 of each tubular member 42 comprise cut away parts that are located inward from the first and second openings 43a, 44a. The cut-away parts define respective channels 43b, 44b that extend in a direction perpendicular to the long axis of the tubular member 42. The first end 43 comprises a u-shaped channel 43b while the second end 44 comprises an n- shaped channel 44b. The u-shaped and n-shaped channels 43b, 44b are substantially the same size and shape and are positioned so that, in use, the n-shaped channel 43b of one tubular member 42 faces and engages the u-shaped channel 44b of another tubular member 42 arranged transversely thereto. The tubular members 42 are then welded together along the adjacent edges of the members forming the channels. The rigid hash- shaped frame is then welded to the legs 32 as shown in Figure 1 to provide a rigid support structure for the container. As best shown in Figure 1 , the tubular members 42 are spaced at the same height from the bottom of the legs 32, meaning the first and second openings 43a, 44a of each tubular member 42 are accessible in the same plane. This has the advantage of standardising fork entry from all sides. It also has the benefit of providing a substantial flat area beneath the base 41 so that the base 41 (and therefore the assembly 100) can be lifted and transported securely by a pallet truck. Due to the tubular members 42 being spaced at the same height from the bottom of the legs 32, the container 10 is also able to sit closer to the ground thereby lowering its centre of gravity. It also creates strapping points low to the ground for transportation, where straps can loop between the first and second ends 43, 44 at each comer of the base 41.

[0048] As best shown in Figure 7, the base 41 comprises four sides and each side comprises a first opening 43 a and a second opening 44a which, in use, define a pair of access points for receiving the forks of a forklift or pedestrian truck. Since the base 41 of the assembly 100 has ‘four-way access’ and can receive the forks of a forklift or pedestrian truck from the front, rear and from both sides, this facilitates handling and movement of the assembly 100 within a warehouse or AM facility.

[0049] Depending on the size of the container 10 the assembly 100 may comprise a plurality of rectangular braces plates (not shown). For example, for larger containers 10 such as those shown in Figures 1-3 that are configured to hold heavier loads, e.g., 500 L of powder, each side of the assembly 100 may be provided with a brace plate which extends between and is substantially perpendicular to a pair of legs 32. For smaller assemblies which are configured to hold lighter loads, e.g., 250 L of powder, the brace plates can still be provided but are not strictly necessary. To dissipate the build-up of electrostatic charge the assembly 10 is provided with an earthing point 45 in the form of a stainless-steel stud. The stud is welded within a hole formed in the wall of at least one leg 32. However, in other embodiments the stud may be threadedly connected to the leg 32. As best shown in Figures 1-3, the container 10 comprises a holder 46 for storing documents which is fixed to an exterior surface of one of the side walls 15. Display information 47 may also be provided on an exterior surface of the base 41 as shown in Figure 3.

[0050] The one or more embodiments are described above by way of example only. Many variations are possible without departing from the scope of protection afforded by the appended claims.

Claims

CLAIMS1. A base for providing support to a structure to which the base is attached, wherein the base comprises four-sides and each side comprises a pair of openings for receiving the forks of a forklift or a pedestrian truck, and wherein the openings are accessible in the same plane.

2. A base according to claim 1, wherein the base comprises four connected tubular members.

3. A base according to claim 2, wherein the tubular members are arranged to define a hash-shaped frame.

4. A base according to claim 3 , wherein the hash-shaped frame comprises a central open area.

5. A base according to any of claims 2 to 4, wherein the tubular members have a rectangular cross-section.

6. A base according to any of claims 2 to 5, wherein each tubular member comprises a first end having a first opening and a second end having a second opening.

7. A base according to any of claims 2 to 6, wherein each tubular member comprises a channel that extends in a direction perpendicular to the long axis of the tubular member.

8. A base according to claim 7, wherein each tubular member comprises a first channel positioned inward from the first opening and a second channel positioned inward from the second opening.

9. A base according to claim 8, wherein the first channel of one tubular member is arranged to face the second channel of another tubular member positioned transversely thereto.

10. A base according to claim 8 or claim 9, wherein the first channel is a u-shaped channel, and the second channel is a n-shaped channel.

11. A base according to claim 10, wherein the tubular members are arranged so that the base comprises a planar top surface.

12. A base according to any of claims 2 to 11, wherein the tubular members are formed from a metal or metal alloy.

13. A base according to claim 12, wherein the tubular members are welded together.

14. An assembly comprising a container, a base and a plurality of support legs attached to the container and to the base, wherein the base is the base according to any of claims 1 to 13.

15. An assembly according to claim 14, wherein the assembly comprises at least four support legs.

16. An assembly according to claim 15, wherein the base is attached to each support leg at a lower end thereof.

17. An assembly according to any of claims 14 to 16, wherein the support legs are attached to the base at an intersection defined by two transversely arranged tubular members.

18. An assembly according to claim 14 to 17, wherein the container, the support legs and the base comprise a metal or metal alloy and are welded together.

19. A method of assembling a base for providing support to a structure, the method comprising the steps of: a. providing four tubular members having first and second openings for receiving the forks of a forklift or pallet truck; and b. arranging the tubular members to provide a hash-shaped frame, wherein the hash-shaped frame comprises four sides and the openings are accessible in the same plane.

20. A method according to claim 19, wherein each tubular member comprises a first channel located inward from the first opening and a second channel located inward from the second opening and wherein the method comprises the step of arranging the tubular members so that the first channel of one tubular member faces the second channel of another tubular member positioned transversely thereto.

21. A method according to claim 19 or claim 20, which comprises the step of securing the tubular members together.

22. A method according to claim 21 , wherein the tubular members comprise a metal or metal alloy and are welded together.

23. A method according to any of claims 19 to 22, wherein the base is subjected to a mechanical and / or chemical treatment to provide a smooth planar top surface.

24. A tubular member comprising a first end having a first opening and a second end having a second opening, wherein a first channel is provided inward from the first opening and a second channel is provided inward from the second opening, and wherein the channels are arranged perpendicular to the long axis of the tubular member.

25. A tubular member according to claim 24, wherein the first channel is a u-shaped channel and the second channel is a n-shaped channel.

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