Patent Publication Number: US-2021179388-A1

Title: Glass elevator innovations

Description:
RELATED APPLICATIONS 
     This application claims priority from pending U.S. Provisional Patent Application No. 62/737,198, filed Sep. 27, 2018, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     Elevators designed for vertical transportation typically operate between vertically-oriented building floors and can be configured for both commercial and residential use. 
     Commercial and residential elevators often operate by moving an enclosure (typically referred to as a cab or car) along one or more guide rails using a cable or hydraulic lift system. The enclosure includes a floor, walls and a ceiling and defines a compartment for goods and/or passengers. The enclosure moves vertically along the guide rails within a hoistway. 
     In certain instances, the enclosure can be configured to provide visibility into and out of the enclosure. The visibility results from the use of transparent materials for floor, wall and ceiling elements, such as the non-limiting examples of acrylics and glass. 
     It would be advantageous if glass elevators could be improved. 
     SUMMARY 
     It should be appreciated that this Summary is provided to introduce a selection of concepts in a simplified form, the concepts being further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of this disclosure, nor is it intended to limit the scope of the innovations for glass elevators. 
     The above objects as well as other objects not specifically enumerated are achieved by a floor for use with a glass elevator. The floor includes an upper major surface, a lower major surface opposing the upper major surface, a first side edge, a second side edge, the first and second side edges extending from the upper major surface to the lower major surface. The floor includes one or more front edges and one or more rear edges. The one or more front edges and one or more rear edges extend from the upper major surface to the lower major surface. The floor is formed from a unitary, continuous, solid plate material. 
     The above objects as well as other objects not specifically enumerated are also achieved by a framework assembly for use with a glass elevator. The framework assembly includes a lower structural ring, an intermediate structural ring positioned vertically above the lower structural ring, a plurality of corner members extending from the lower structural ring to the intermediate structural ring and a plurality of guide rails extending from the lower structural ring to the intermediate structural ring. The lower and intermediate structural rings are each formed from a unitary, continuous, solid plate material. 
     The above objects as well as other objects not specifically enumerated are also achieved by a cladding member for use with glass elevator. The cladding member includes a first base portion and a first side portion extending from the first base portion. The cladding member also includes a second base portion opposing the first base portion and a second side portion extending from the second base portion. A top portion extends from the first side portion to the second side portion. A cavity is formed by the first and second base portions, first and second side portions and the top portion. The cavity is configured to receive a portion of a guide rail. 
     The above objects as well as other objects not specifically enumerated are also achieved by a method of cold forming a radiused bend in transparent materials for use with a glass elevator. The method includes the steps of selecting a punch for use in a press brake, the punch having a cross-sectional shape with a desired radius, selecting a die for use with the punch in the brake press, the die having cross-sectional shape that corresponds with the cross-sectional shape of the punch, the die having an opening configured to receive the punch, positioning a material on the die such that an intended bend line aligns with the cross-sectional shape of the die, urging the punch into contact with the material without the use of heat until the material seats against the die and forms a bend and urging the punch out of contact with the material. The die opening has a dimension in a range of from about 5 to 8 times a thickness of the transparent material. 
     Various objects and advantages of the innovations for glass elevators will become apparent to those skilled in the art from the following detailed description, when read in light of the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a glass elevator car. 
         FIG. 2  is a perspective view of a first embodiment of a floor of the glass elevator car of  FIG. 1 . 
         FIG. 3  is a perspective view of a second embodiment of a floor of the glass elevator car of  FIG. 1 . 
         FIG. 4  is a perspective view of a framework assembly for an elevator hoistway of the glass elevator car of  FIG. 1 . 
         FIG. 5A  is a perspective view of a structural ring of the framework assembly of  FIG. 4 . 
         FIG. 5B  is a plan view of a structural ring of the framework assembly of  FIG. 4 . 
         FIG. 6  is a perspective view of a guide rail of the framework assembly of  FIG. 4 . 
         FIG. 7  is a plan view of a guide rail of the framework assembly of  FIG. 4 . 
         FIG. 8  is a perspective view of a cladding member for use with the framework assembly of  FIG. 4 . 
         FIG. 9  is a perspective view of the guide rail of  FIGS. 6 and 7  and the cladding member of  FIG. 8 , shown in a pre-assembled orientation. 
         FIG. 10  is a plan view of the guide rail of  FIGS. 6 and 7  and the cladding member of  FIG. 8 , shown in an assembled orientation. 
         FIG. 11  is a perspective view of a framework assembly of  FIG. 4  illustrating the installed cladding members of  FIG. 8 . 
         FIG. 12  is a perspective view of a front wall element of the glass elevator car of  FIG. 1 , illustrating a radiused bend. 
         FIG. 13  is a perspective view of a CNC press brake used to form the radiused bend of the front wall element of  FIG. 11 . 
         FIG. 14A  is a schematic illustration of the punch and a corresponding die of the CNC press brake illustrated in  FIG. 13 . 
         FIG. 14B  is a schematic illustration of the punch and a corresponding die of the CNC press brake illustrated in  FIG. 13 , shown with a material positioned on the die of  FIG. 14A . 
         FIG. 14C  is a schematic illustration of the punch and a corresponding die of the CNC press brake illustrated in  FIG. 13 , shown with the punch of  FIG. 14A  engaging the material of  FIG. 14B . 
     
    
    
     DETAILED DESCRIPTION 
     The innovations for glass elevators (hereafter “glass elevator innovations”) will now be described with occasional reference to the illustrated embodiments. The glass elevator innovations may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the glass elevator innovations to those skilled in the art. 
     Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the glass elevator innovations belong. The terminology used in the description of the glass elevator innovations herein is for describing particular embodiments only and is not intended to be limiting of the glass elevator innovations. As used in the description of the glass elevator innovations and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. 
     Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the glass elevator innovations. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the glass elevator innovations are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements. 
     The description and figures disclose innovations for glass elevators. The innovations include a floor formed from unitary, continuous, solid plate material, a plurality of structural rings formed from a unitary, continuous, solid plate material, cladding members configured for attachment to guide rails and radiused bends formed in various car elements by cold forming processes. 
     The term “glass”, as used herein, is defined to mean transparent materials, such as the non-limiting examples of transparent materials include polymeric materials, glass materials or any combination thereof. The use of the glass materials in elevator wall elements, floor elements or ceiling elements advantageously allows for visibility out of the elevator car or into the elevator car. The term “elevator”, as used herein, is defined to mean any structure configured for vertical transportation, including the non-limiting examples of commercial elevators, residential elevators, service elevators, dumb-waiters, wheel-chair lifts, platform lifts, passenger elevators and the like. 
     Referring now to the drawings, there is illustrated in  FIG. 1  a non-limiting example of a glass elevator car at  10 . In the illustrated embodiment, the glass elevator car  10  is configured for a residential elevator. However, in other embodiments, the glass elevator car  10  can be configured for other types of elevators. The glass elevator car  10  is configured for guidance by one or more guide rails (not shown) and further configured for vertical travel within a hoistway (not shown). The glass elevator car  10  includes a floor element  12 , a ceiling element  14 , a plurality of front wall elements  16   a ,  16   b , opposing sidewall elements  18   a ,  18   b  and a rear wall element  20 . The floor element  12 , ceiling element  14 , front wall elements  16   a ,  16   b , opposing sidewall elements  18   a ,  18   b  and the rear wall element  20  are connected together by elements of a framework assembly  22 . The framework assembly  22  will be discussed in more detail below. 
     To facilitate visibility into and out of the interior of the glass elevator car  10 , portions of the front wall elements  16   a ,  16   b , opposing sidewall elements  18   a ,  18   b  and the rear wall element  20  can be formed from transparent materials. 
     Referring now to  FIG. 2 , a first embodiment of the floor element  12  is illustrated. The floor element  12  includes a major upper surface  24  and a major lower surface  26 . The floor element  12  further includes a first side edge  28 , a second side edge  30 , a first front edge  32   a , a second front edge  32   b , a first rear edge  34   a  and a second rear edge  34   b . The floor element  12  can include a plurality of first recesses  36  arranged to be adjacent and parallel to the first and second side edges  28 ,  30 . The recesses  36  are configured as guides for the cab gate (not shown). The floor element  12  can include a plurality of apertures  38  for attaching cab walls, and second recesses  40  configured to receive cab sling attachments (not shown). The floor element  12  is formed from unitary, continuous, solid plate material, such as the non-limiting examples of aluminum plate or reinforced fiberglass plate. The unitary, continuous, solid plate provides the required strength, while maintaining a low profile and a low weight. Prior to machining, the floor element  12  has a rectangular shape. 
     Referring again to  FIG. 2 , forming the floor element  12  from a unitary, continuous, solid plate material provides many benefits, although all benefits may not be present in all embodiments. First, forming the floor element  12  from unitary, continuous, solid plate material facilitates a pitless elevator hoistway structure, thereby requiring a distance of only 0.75 inches of step into the glass elevator car  10 . Second, the floor element  12  formed from unitary, continuous, solid plate material facilitates a shallow pit hoistway structure, thereby resulting in no step up distance into the glass elevator car  10 . Third, the floor element  12  formed from unitary, continuous, solid plate material facilitates the manufacture of any shape or size of floor element  12 . Fourth, the floor element  12  formed from unitary, continuous, solid plate material facilitates incorporation of the sill and gate track into the floor element  12 , thereby providing an efficient manufacturing process. Fifth, the floor element  12  formed from unitary, continuous, solid plate material facilitates a simpler manufacturing process as welding steps are no longer needed. Sixth, the floor element  12  formed from unitary, continuous, solid plate material provides a corrosion-resistant material. Finally, the floor element  12  formed from unitary, continuous, solid plate material provides an aesthetically pleasing sleek and modern appearance. 
     Referring now to  FIG. 3 , a second embodiment of the floor element  112  is illustrated. The floor element  112  includes a major upper surface  124 , a major lower surface  126 , a first side edge  128 , a second side edge  130 , a first front edge  132   a , a second front edge  132   b , a first rear edge  134   a  and a second rear edge  134   b . In the illustrated embodiment, the major upper surface  124 , major lower surface  126 , first side edge  128 , second side edge  130 , first front edge  132   a , second front edge  132   b , first rear edge  134   a  and second rear edge  134   b  are the same as, or similar to, the major upper surface  24 , major lower surface  26 , first side edge  28 , second side edge  30 , first front edge  32   a , second front edge  32   b , first rear edge  34   a  and second rear edge  34   b  shown in  FIG. 2  and described above with the exception that the first major surface  124  includes a recess  146 . The recess  146  is arranged to abut the edges  128 ,  130 ,  132   a ,  132   b ,  134   a  and  134   b . The recess  146  is configured to receive flooring (not shown). The flooring can have any decorative or functional form and the recess  146  can have any depth, shape or size sufficient to receive the flooring. 
     Referring again to  FIG. 3 , in a manner similar to the floor element  12 , the floor element  112  is formed from unitary, continuous, solid plate material and is configured to provide the same benefits as described above for the floor element  12 . 
     Referring now to  FIG. 4 , the framework assembly  22  is illustrated in an exploded view. When assembled, as shown in  FIG. 1 , the framework assembly  22  provides a supporting structure within which the residential elevator car  10  travels. The framework assembly  22  includes a lower structural ring  50   a , an intermediate structural ring  50   b  and an upper structural ring (not shown for purposes of clarity). The lower and intermediate structural rings  50   a ,  50   b  are connected to a plurality of substantially vertical corner members  52   a - 52   d  and also connected to a plurality of guide rails  54   a ,  54   b . The intermediate and upper structural rings  50   a  are connected to a plurality of substantially vertical corner members  56   a - 56   d  and also connected to a plurality of guide rails  58   a ,  58   b.    
     Referring now to  FIGS. 5A and 5B , the lower structural ring  50   a  is illustrated. The lower structural ring  50   a  is representative of the intermediate structural ring  50   b . The lower structural ring  50   a  includes an aperture  60  bounded by a plurality of perimeter segments  62   a - 62   e . The perimeter segments  62   a - 62   e  and the aperture  60  cooperate to allow passage of the residential elevator car  10  therethrough. In the illustrated embodiment, the perimeter segments  62   a - 62   e  cooperate to form the five-sided lower structural ring  50   a . However, it should be appreciated that in other embodiments, more or less than five perimeter segments can be used and the resulting structural ring can have other shapes and configurations. 
     Referring again to  FIGS. 5A and 5B , the lower structural ring  50   a  includes a plurality of corner tabs  64   a - 64   d  and a plurality of intermediate tabs  66   a ,  66   b . The plurality of corner tabs  64   a - 64   d  extend in a direction perpendicular to a plane formed by the perimeter segments  62   a - 62   e  and are configured to receive the corner members  52   a - 52   d . The plurality of intermediate tabs  66   a ,  66   b  extend in a direction perpendicular to a plane formed by the perimeter segments  62   a - 62   e  and are configured to receive the guide rails  54   a ,  54   b.    
     Referring again to the embodiment shown in  FIGS. 4, 5A and 5B , the lower structural ring  50   a  is formed from a unitary, continuous, solid plate material, such as the non-limiting examples of unitary steel plate or unitary aluminum plate. The unitary, continuous, solid plate material is configured to provide structural strength while maintaining a low aesthetic profile, and allows the creation of complex custom shapes. The lower, intermediate and upper structural rings  50   a ,  50   b  can have a thickness in a range of from about 0.375 inches to about 0.75 inches. In certain instances, the lower, intermediate and upper structural rings  50   a ,  50   b  are formed using CNC-style plasma-based or laser-based cutting apparatus. However, it is contemplated that other methods can be used to form the lower, intermediate and upper structural rings  50   a ,  50   b  from unitary, continuous, solid plate material. 
     Referring now to  FIGS. 4, 5A and 5B , the lower, intermediate and upper structural rings  50   a ,  50   b , formed from unitary, continuous, solid plate material provides many benefits, although all benefits may not be present in all embodiments. First, the lower, intermediate and upper structural rings  50   a ,  50   b , formed from unitary, continuous, solid plate material facilitate easy creation of custom structural ring shapes and sizes, including the non-limiting examples of non-square, non-rectangular, non-circular and non-ovular shapes. Second, the lower, intermediate and upper structural rings  50   a ,  50   b , formed from unitary, continuous, solid plate material facilitate easy and fast construction of the framework assembly  22 . Finally, the lower, intermediate and upper structural rings  50   a ,  50   b , formed from unitary, continuous, solid plate material facilitate building of the framework assembly  22  in small and/or limited hoistway spaces. 
     Referring now to  FIGS. 6 and 7 , a non-limiting example of a guide rail  54   a  is illustrated. The guide rail  54   a  is representative of the guide rails  54   b ,  58   a  and  58   b . The guide rail  54   a  has an inverted “T” cross-sectional shape and includes a guiding web  70  extending from a base  72 . The guiding web  70  includes a front face  74   a  positioned between opposing side faces  74   b ,  74   c . The base  72  includes opposing flanges  76   a ,  76   b . In operation, the glass elevator car  10  rolls or slides against the face  74   a  of the guide rails  54   a  as the glass elevator car  10  moves within the framework assembly  22 . 
     Referring now to  FIG. 8 , a cladding member  80  is illustrated. The cladding member  80  includes a first base portion  82   a  and a first side portion  84   a  extending from the first base portion  82   a . In a similar manner, a second side portion  84   b  extends from a second base portion  82   b . A top portion  86  connects the first and second side portions  84   a ,  84   b . The first and second base portions  82   a ,  82   b , first and second side portions  84   a ,  84   b  and the top portion  86  cooperate to form a cavity  88  therebetween. The cavity  88  extends a length of the cladding member  80  and has a rectangular cross-sectional shape. The first and second base portions  82   a ,  82   b  are spaced apart such as to form a slot  90  therebetween. The slot  90  extends the length of the cladding member  80 . 
     Referring again to  FIG. 8 , the cladding member  80  is formed from a metallic material, such as for example, stainless steel. Alternatively, the cladding member  80  can be formed from other desired metallic materials, including the non-limiting examples of galvanized steel, aluminum, copper and brass. 
     Referring now to  FIGS. 9 and 10 , the cladding member  80  is attached to the guide rail  54   a  by sliding a connector member  92  (commonly called a fishplate) into the cavity  88 . Next, a plurality of fasteners  94  are inserted into and through clearance apertures  96  in the guide rail  54   a  and into corresponding threaded apertures  98  located in the connector member  92 . In the illustrated embodiment, the fasteners  94  are threaded bolts. However, in other embodiments, the fasteners  94  can be other structures, such as the non-limiting examples of clips or clamps. 
     Referring again to  FIGS. 9 and 10 , the plurality of fasteners  94  are tightened until the base  72  of the guide rail  54   a  seats against the first and second base portions  82   a ,  82   b  of the cladding member  80 . Tightening of the plurality of fasteners  94  continues until the guide rail  54   a  is secured attached to the cladding member  80 . The attachment of the cladding member  80  to the guide rail  54   a  continues until the cladding member  80  completely covers the base portion  72  of the guide rail  54   a , as shown in  FIG. 11 . Used in this way, the cladding members  80  can present an aesthetically pleasing appearance rather than the industrial appearance of the base portion of the guide rails  54   a.    
     Referring again to the embodiment shown in  FIGS. 8-11 , the cladding members  80  are formed from metallic extrusions, the appearance of which can be customized to provide a desired aesthetic appearance and style to the hoistway. It is contemplated that the cladding members  80  can have colorings, coverings, coatings and/or textures that serve to visually compliment the desired ornate appearance of the highlighted technical and functional components of the building. For example, if the desired ornate appearance of the highlighted technical and functional components is best complimented by natural metallic finishes, then the cladding members  80  can be provided with a natural finish or with clear finishes. As another example, if the desired ornate appearance of the highlighted technical and functional components is best complimented by tinting the cladding members  80  with one or more colors, then the cladding members  80  can be provided with any desired coloring or colorings. As yet another example, if the desired ornate appearance of the highlighted technical and functional components is best complimented by a specialized coating, then the cladding members  80  can be provided with any desired coating, such as the non-limiting examples of chrome, nickel or cadmium plating. 
     Referring again to the embodiment shown in  FIG. 8 , the first and second side portions  84   a ,  84   b  and the top portion  86  of the cladding members  80  have a substantially smooth surface. The term “smooth surface”, as used herein, is defined to mean a continuous, even surface. The smooth surfaces of the first and second side portions  84   a ,  84   b  and the top portion  86  are configured to provide one aesthetic appearance to the cladding member  80 . Optionally, the first and second side portions  84   a ,  84   b  and the top portion  86  of the cladding member  80  can be textured. The term “textured”, as used herein, is defined to mean having a non-smooth surface characteristic. The textures imparted to the first and second side portions  84   a ,  84   b  and the top portion  86  can provide other desired aesthetic appearances to the cladding member  80 . The textures can be formed by any desired structure or combination of structures, including the non-limiting examples of grooves, cross-hatchings or granulations. 
     Referring again to  FIG. 8 , the cladding members  80  provide many benefits, although all benefits may not be present in all embodiments. First, the cladding members  80 , when attached to the guide rails  54   a ,  54   b ,  58   a ,  58   b  form a very strong structural frame that provides additional structural rigidity to the framework assembly  22 . Second, the cladding members  80  facilitate use of industry standard guide rails  54   a ,  54   b ,  58   a ,  58   b , while presenting an aesthetically appealing finished product. Finally, the cladding members  80  facilitate easy assembly of the framework assembly  22 . 
     While the embodiment illustrated in  FIGS. 9-11  illustrate the use of guide rails  54   a ,  54   b ,  58   a ,  58   b  having a “T” cross-sectional shape, it is contemplated that the cladding members  80  can be configured for attachment to guide rails having other cross-sectional shapes. 
     Referring again to  FIG. 1  and as previously discussed, the front wall elements  16   a ,  16   b , opposing side wall elements  18   a ,  18   b  and the rear wall element  20  can be formed from transparent materials, such as the non-limiting example of polymeric materials. In certain instances, it is desirable to form radiused bends, arcuate shapes and/or corners in the transparent materials. Typically, polymeric materials can formed into shapes by processes involving simultaneous applications of heating and bending. However, the thermal forms for these processes can be expensive and limited to forming specific shapes. Referring now to  FIG. 12 , a front wall element  16   a  is illustrated. The front wall element  16   a  includes a first leg  100 , a second leg  102  and a radiused bend  104  therebetween. In this embodiment, the radiused bend  104  is formed by a cold forming process, that is, a non-heat related process. The cold forming process uses a computer numerical control (commonly referred to a “CNC”) press brake for creating of custom shapes for materials used in elevator cabs and hoistways. One non-limiting example of a CNC press brake is shown at  106  in  FIG. 13 . In the illustrated embodiment, the press brake  106  is a Model B120/200, manufactured and marketed by Iroquois Ironworker, Inc., headquartered in Iroquois, South Dakota. However, in other embodiments, other suitable press brakes can be used. 
     Referring now to  FIGS. 14A-14C , the novel process for cold forming the radiused bends used in the front wall elements  16   a ,  16   b , opposing side wall elements  18   a ,  18   b  and the rear wall element  20  will now be described. In a first step, a suitable punch  160  is matched with a corresponding die  162 . The die  162  has an opening  164  with a cross-sectional shape of a V. The opening  144  has a base dimension of d. The base dimension d corresponds to a thickness t of the material  166  to be cold formed. In the illustrated embodiment, the base dimension d is approximately 5-8 times the thickness t of the material  166 . In one non-limiting example, the material  166  has a thickness t of about 0.25 inches and the base dimension d of the opening  164  is in a range of from about 1.25 inches to about 2.00 inches. Without being held to the theory, it has been found that linking the base dimension d to about 5-8 times the thickness t of the material  166  advantageously helps prevent cracking of the material  126  during the cold forming process. 
     Referring now to  FIG. 14B  in a next step, the material  166  is positioned on the die  162  in a manner such that the intended bend line of the material  166  is aligned with the V. In a next step, force is applied to the punch  160  in an manner such as to move the punch  160  toward the material  166  and the die  162 , as indicated by direction arrow F. 
     Referring now to  FIG. 14 c    in a next step, movement of the punch continues until the punch  160  contacts and drives the material  166  into the opening  164  and against the die  162 . Once the material  166  is seated against the die  162 , the material  166  has been bent into a radiused bend without the use of heat. The force used on the punch  160  depends on the thickness t of the material  166 , the dimension d of the opening  164  and the desired inner radius of the formed material  166 . In the illustrated embodiment, it has been found that the force can be determined from common press brake tonnage charts as used for sheet metals. However, in other embodiments, other references can be used to determine the required force. 
     Advantageously, the use of the CNC press brake  106  allows creation of cold forming processes to form custom angles specific to an elevator installation. The use of the CNC press brake  106  provides for easily customizable shapes without costly thermal-related forms, and results in clean and crisp radiused bends  104 . 
     While the embodiments shown in  FIGS. 1-4, 5A, 5B, 6-13 and 14A-14C  have been described in the context of an elevator having elevator wall elements, floor elements or ceiling elements advantageously cold formed with glass materials or polymeric materials, it is further contemplated that the described innovations can be incorporated into an elevator having elevator wall elements, floor elements or ceiling elements formed with other cold formed materials, such as the non-limiting examples of metal and/or wood. 
     In accordance with the provisions of the patent statutes, the principle and mode of operation of the innovations for glass elevators have been explained and illustrated in a certain embodiment. However, it must be understood that the innovations for glass elevators may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.