Patent Publication Number: US-2022234150-A1

Title: Method of Using Improved Crossbar Connection for Implements

Description:
CLAIM OF PRIORITY 
     This application is a continuation of U.S. patent application Ser. No. 16/137,746 filed Sep. 21, 2018, which claims the benefit of U.S. Provisional Patent Application No. 62/561,735 filed Sep. 22, 2017, both of which are incorporated hereby by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to heavy equipment, such as front end loaders, excavators and the like that use implements, normally secured to the heavy equipment with couplers which receive a crossbar portion within a connection zone to connect the implement to the coupler, and thus the heavy equipment. 
     BACKGROUND OF THE INVENTION 
     U.S. Pat. No. 7,866,935, incorporated herein by reference in its entirety, provides a coupler for use with heavy equipment, such as excavators, mini-excavators or other equipment. That device has an adjustment member within the jaws of a C-channel to be able to more securely connect crossbars of implements to the connector. The coupler of the &#39;935 patent has been found to work very well. 
     However, with roughly 650 implement manufacturers, the tolerances of the crossbars to be received within couplers can still create issues for the users of such equipment. Specifically, the current way of manufacturing the crossbar is to take a section of pipe and weld onto it attachment plates at a top and bottom portion of the pipe in the connection zone. The attachment plates can be machined and then placed on the pipe which necessarily provides an interface between the two, and then the attachment plates are secured to the pipe with a top and bottom weld. The attachment plate is also located spaced from a center line when connected, thereby reducing a length of a potential planar surface. The excess weld material from the top weld is then normally machined or ground off in an effort to have an outer surface of the top attachment plate be parallel to the bottom attachment plate, ideally while maintaining a specific spacing therebetween. The total length of the planar surfaces on these crossbars of these planar portions is less than ¼ inch, if not less than ½ inch, and maintaining spacing and parallel relationships across the planar surfaces has been found to be extremely difficult for manufacturers. There are also voids which occur below the top weld and internal to the bottom weld, which together with the interface of the attachment plate to the pipe provide localized stress points or locations from which brittle failure, stress failure or other failure mechanisms can originate and/or propagate, particularly over time. 
     Additionally, there are now at least three if not four separate materials in the connection zone of the crossbar: (1) the pipe, (2) the attachment plates, (3) the top weld and (4) the bottom weld. There are also necessarily distinct separations which occur between at least some of these components. 
     Accordingly, there is believed to be a need for an improved crossbar construction for an implement over these prior art designs which can give rise to more repeatable accuracy in the parallel nature of the surfaces, an increased length of planar connection surfaces, and/or possibly increased strength and/or a reduced likelihood of failure over time due to separation locations and/or voids within the crossbar construction. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of many embodiments of the present invention to provide an improved crossbar construction having a uniform cross section at least along the hookup location (connection zone) of a single unitary material that is void-free and/or interface free. 
     As another object of many embodiments of the present invention to provide an improved crossbar construction utilized with implements having one of an extruded and a cast construction of unitary nature, at least in the connection zone, whereby consistently parallel connection surfaces are integrally formed with the remainder of the crossbar to thereby eliminate separation locations/interfaces and/or voids within at least the connection zone. 
     Crossbar constructions for an implement, at least in the connection zone, having opposed parallel connection locations that can be longer in planar length than prior art designs, and particularly if made across the entire length of the crossbar instead of only in the connection zone, provide additional strength and resistance to torque over prior art constructions. 
     Accordingly, in accordance with the present preferred embodiment of the present invention, at least one of a cast or extruded crossbar is provided for an implement to be utilized, normally with a coupler. A more secure connection to prevent rattle or vibration after connection can be provided due to the parallel nature of the surfaces employed possibly in combination with the coupler as shown in U.S. Pat. No. 7,866,935. Not only can the attachment locations be longer than prior art constructions, they can be stronger and be interface-free/void-free to thereby be less susceptible to failure over time. 
     As described above with the prior art, the attachment plates are welded at a top and bottom location to a pipe with top and bottom welds which in the connection zone and then those welds at least the top welds are ground to attempt to provide planar surfaces. These four welds and then machining step necessarily require a significant amount of labor and expense. By extruding the crossbar, the applicant can maintain a uniform cross section across at least the connection zone, if not the entire implement, thereby not only significantly reducing the cost which has dropped to a savings of possibly over 50% for the crossbar, but also an unexpected increase in strength as verified by finite analysis of the structure over the prior art construction which only had the attachment plates provided in the contact zone, which was difficult enough to attempt to maintain precision of parallelness. 
     With the extruded crossbar member, the applicant has been able to increase the relative surface contact from roughly half an inch (to at most ¼ inch) at the attachment portions of planar material to at or over an inch, or even an inch and a half or more, which provides a more secure locking connection with the coupler of the prior art constructions as well. Not only can this cross section be provided in the connection zone but can be done across the entire crossbar with the extruded constructions. 
     Additionally, cast crossbars could be similarly provided to maintain the precision and/or increased repeatable surface area of the crossbars for at least some embodiments, whether having the improved cross section in the connection zone, across the length of the crossbar, or some construction in between. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which: 
         FIG. 1A  shows a cross sectional of a prior art crossbar in the connection zone; 
         FIG. 1B  shows a detail A of  FIG. 1A ; 
         FIG. 2  is a rear perspective view of the presently preferred embodiment of the present invention; 
         FIG. 3  is a detailed close up view of detail B of  FIG. 2 ; 
         FIG. 4  is a front perspective view of the crossbar shown in  FIGS. 2 and 3 ; 
         FIG. 5  is a cross sectional view taken along line C-C of  FIG. 4 ; 
         FIG. 6  is a rear perspective view of a coupler connected to the crossbar as shown in  FIGS. 2-5  with a crossbar taken out of the attachment; 
         FIG. 7  is a cross sectional view of the structure shown in  FIG. 6  taken along the line D-D; 
         FIG. 8  is a rear perspective view of a first alternative embodiment of the present invention; 
         FIG. 9  is a cross sectional view such as could be taken along the line C-C of  FIG. 4  of a second alternative preferred embodiment; and 
         FIG. 10  is a cross section view such as could be taken along the line C-C of  FIG. 4  of a third alternative preferred embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIGS. 1A and 1B  show a cross-sectional view of a prior art crossbar  10  with first and second attachment plates  12 , 14  being connected with top welds  16 , 18  and bottom welds  20 , 22  to an exterior surface of a pipe  24 . As one of ordinary skill in the art would quickly observe, precisely locating these first and second attachment plates  12 , 14  relative to the pipe  24  is not only tricky but also maintaining the parallel nature of first exposed surface  26  relative to second exposed surface  28  is extremely difficult. 
     The attachment plates  12 , 14  are spaced from the center line  19  when connected. This normally creates a gap  21  which is a loss of potential planar load bearing surface. 
     After performing the top and bottom welds  16 , 18 , 20 , 22  respectively, a machining or grinding step is typically performed whereby at least the top weld  16 , 18  is ground down to be planar with the exposed connection surface  26  to provide first connection plane  30  which would then have a corresponding portion at the bottom portion of pipe  24  as would be understood by those of ordinary skill in the art. It is extremely difficult to maintain the parallel nature of the surfaces. Additionally, when manufacturing these surfaces, there is almost always at least one of a first void  32  in front of at least a portion of the attachment plate  26  and a second void  34  below the connection surface  30  or connection plate  26  as shown. Additional there is also an interface  36  in which the attachment plate  26  contacts an exterior surface  38  of the pipe  24 . It is worthwhile to mention that the attachment plate  26 , the pipe  24  and the welds  16 , 18  are all different materials having different characteristics, such as a 50 Min Yield pipe  24 , a 70 or 80 Min Yield weld material and an A36 (36 Min Yield) attachment plate  26 . The pipe  24  is rarely ground, if ever, in these procedures. 
     Any of the voids  32 , 34  and/or the interface  36  can be a location for stress to propagate as cracks and ultimately failure of either or both of the top and bottom welds  16 ,  20  particularly over time. 
     Additionally, all of the welding steps for creating the top welds  16 , 18  as well as the bottom welds  20 , 22  take an extensive amount of time and labor as well as the machining step(s) in order to attempt to provide the upper and lower connection surface(s)  30 . In many instances, the length  30  of the planar surface of the connection surface  30  is typically a half-inch or less due to the difficulty in providing precision, but certainly not more than three quarters of an inch as represented by length  31  from the center line  19  to an end of the attachment plate  12 , and normally limited to a length of connection surface  30  (since the surface along or at the gap  25  is normally not machined). 
       FIG. 2  shows the first embodiment of a presently preferred embodiment of an attachment  40  in the form of a bucket having a crossbar  42  which typically cooperates with a coupler  44  as shown in  FIGS. 6 and 7  as will be explained in further detail below. The crossbar  42  may be extruded, cast, or otherwise provided, for many embodiments. 
     The crossbar  42  for many preferred embodiments has at least a relatively consistent cross section such as the one shown in  FIG. 5  across its length, such as its entire length for at least some embodiments. Other embodiments may be manufactured differently to have different cross sections along a first portion of its length, such as the embodiment shown in  FIG. 8 , which will be discussed in further detail below. Unlike most pipes, the outer diameter is desired to be within relatively strict tolerances as opposed to the inner diameter which most pipe manufacturers strive to maintain. 
     The crossbar  42  of  FIG. 2  as illustrated has been extruded or cast. It has absolutely no voids, interfaces or separations between the attachment connection or planar portion (i.e, the first and second flats  44 , 46 ) and the interior surface  48  of the crossbar  42  at least in the connection zone  74  as explained below. The cross section of the crossbar  42  could be said to have a unitary or integral construction at least in the connection zone  72 . Accordingly, the first and second voids  32 , 34  shown in  FIG. 1B  are not present in this construction. For many embodiments, this is due to the ability to either cast or extrude the crossbar  42 . One could also machine the crossbar  42  from a larger diameter and thickness of pipe. There are also no interfaces  36  of connecting materials for which a fracture seam may initially already be present as provided by the prior art. A seam free and void free connection of the first and second flats  44 , 46  into the crossbar  42  all the way to the interior surface  48  is believed to provide a more robust crossbar  42 , while also significantly reducing costs over prior art construction techniques. 
     A finite analysis comparing the crossbar  42  to the crossbar  10  of  FIG. 1A  showed a dramatic increase in strength as and resistance to torsion along the length  54 . Furthermore, the first contact plane  50  and the second contact plane  52  are found to be able to be consistently manufactured to be at least an inch if not an inch and a half or more as opposed to the half-inch and certainly not more than three quarters of an inch of the prior art construction due to the difficultly in manufacturing with that technique. 
     While this may not initially sound that significant, when referring to  FIG. 7 , one will see that the first contact surface  50  is shown adjacent an upper wall  62  as well as a lower mouth portion  64  against the second planar face attachment face  52  whether or not it has the adjustable cinching capability  66  as discussed in U.S. Pat. No. 7,866,935 or not. As one can see that these longer contact faces  50 , 52  extending from center line  51  provide for a longer snugger contact surface  50 , 52  and tighter fit within the coupler  44  which previously has not been achieved in the prior art. In fact, contact faces  50 , 52  can extend across the other or opposite side of center line  51  (something that has not happened with prior art constructions as they are currently manufactured) See  FIG. 10 . For many embodiments, there is no gap  21  between the attachment surfaces  50 , 52  and the center line along those planar surfaces. The surface contact area provided by the first and second contact planes is more than double the prior art for many embodiments, but at least 33% greater. This can reduce rattle for at least many embodiments. 
     In order to make the connection of  FIG. 7 , normally the crossbar  42  as shown in  FIG. 7  is rotated towards the right so that the first contact face  50  is angled at least partially downwardly thereby permitting more of a round cross section portion as opposed to the planar flats  50 , 52  being introduced into the channel  68  which can then effectively be rotated to provide a bite and/or mechanical bind nature as is shown particularly with the use of the adjustment  66  (of U.S. Pat. No. 7,866,395, if used) to help secure that connection in a tight and non-rattling manner. 
     In the prior art, the more non-planar the first attachment plate was from the second attachment plate the less contact surface occurred between the attachment plates and the side channel walls, and thus more rattle and play which is believed to be undesirable to operators and/or others. This rattle can be significantly reduced, and many times eliminated completely with the applicant&#39;s construction. 
     In the manufacture of a bucket as an attachment  40  certainly crossbar  42  can extend from first side  70  to second side  72 . However, for other embodiments, it may only be necessary for the improved cross section of the crossbar  42  to be in the connection zone  74 , or a portion thereof, such as where the coupler  45  connects to the crossbar  42  as would be understood by those of ordinary skill in the art, and there could be additional structures to support the crossbar  42  outside of the connection zone  74  for various embodiments. One such possibility is shown in  FIG. 8  which is discussed in further detail below. Certainly, other implements or attachments  40  can connect with a similar or dissimilar coupler  55  other than the bucket embodiment illustrated. 
     The crossbar  42  is shown also extending at a top  76  of the attachment  40  and therefore assisting in defining the opening  78  into which the material can enter the attachment  40  when provided as a bucket as would be understood by those of ordinary skill in the art. While the coupler  45  may provide an adjustment mechanism  66 , not all couplers  45  will have such a capability. The new precision of being able to provide for the height  80  and know the parallel nature of the flats  44 , 46  with a high degree of accuracy, as compared to the width  82  of the channel  68  of the coupler,  45 , the ability to insert the crossbar  42  into the coupler  44  as would be understood by those ordinarily skilled in the art as described above with the round surfaces  49  of the crossbar  42  first directed into the channel  68  and then rotated to mechanically bind with the flats  44 , 46  is drastically improved. While the crossbar  42  is shown as having a principally round surface  49  apart from the flats  44 , 46 , other embodiments could take on other shapes. 
     With the crossbar  42  received in the channel  68  of the coupler  44  as shown in  FIG. 6 , the bottom  84  is above the receiver  86  to then be able to insert a pin through first and second bores  88 , 90  to then secure the attachment  40  to the coupler  44 . 
     For some embodiments, the crossbar  42  has a stop  92  which can connect to back  94  of an attachment  40 , such as a bucket outside of the connection zone  74 . This can provide for more precise location of the first flat  44  within the connection zone  74  than prior art techniques as well, if not a more rigid attachment  40 , and thus possibly a stronger attachment  40 . 
     Some embodiments provide a 4.5-inch diameter for a crossbar width  96 , which may be slightly shorter than height  80 . Other embodiments provide a 2.88-inch diameter, but other embodiments could use still other dimensions. 
       FIG. 8  shows a first alternatively preferred embodiment of an attachment  100  having a crossbar  102  with this attachment  100  having the cross section shown in  FIG. 5  in the connection zone  104 , but possibly a more pipe-like cross section (i.e., more round) outside of the connection zone  104  for zones  112 , 114 . This construction could be made by casting the crossbar  102  or other methodology. Once again there are no voids separating the first and second attachment planes  106 , 108  from internal surfaces  110  of the crossbar  102  as exists in the prior art construction and certainly there is no interface contact between an adjustment plate and a pipe thereby giving a location for a potential stress fracture possibly with void(s), since the attachment planes are integrally formed into the crossbar  102  in a similar manner as the crossbar  42  in the connection zone. No party is known to have cast a crossbar  102  as shown and described herein. 
       FIG. 9  provides a cross section of a second alternatively preferred embodiment showing a crossbar  200  having attachment surfaces  202 , 204  with respective flats  206 , 208  extending preferably to the centerline  210 . This embodiment may be extruded or cast. This design can be symmetrical about axis  212  for some embodiments. Stops  214 , 216  can be similar or different in shape as attachment surfaces  202 , 204 . Ends  218 , 220  may be rounded, pointed, flats or have other shapes. When flats are provided at ends,  218 , 220 , corners  222 , 224  may be rounded or not. Wall thickness  226  may vary or be relatively consistent for various embodiments (other than at flats  206 , 208  and/or stop  214 , 216 ). 
       FIG. 10  shows a cross section similar to  FIG. 9  except ends  302 , 304  of crossbar  300  are rounded points and other minor differences. For instance, flats  300 , 310  extend to the opposite side of center line  306 . Other embodiments could be constructed differently. 
     Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. 
     Having thus set forth the nature of the invention,