Patent Description:
Machines, such as excavators, are used in a wide variety of applications including construction, mining, road building, and trenching. In each application, an excavator may use a bucket to penetrate into a pile of material, or a work surface such as the ground, to scoop up the material, and subsequently dump it in a desired location. The bucket is a key component in efficiently performing the desired operation.

While performing a material moving or digging operation, the bucket may be subjected to extreme loads and wear. In addition to withstanding significant loads, the bucket must also be constructed to endure a desired number of cycles or hours of operation. If a bucket fails, in addition to the cost to repair or replace the bucket, the failure may result in lost productivity. Typically, buckets are made from a plurality of welded-together pieces. The welded joints of such buckets, especially in the area of the hinge assembly on the bucket, are areas where cracks and failures due to fatigue stress can occur.

<CIT>, entitled "Integrally Cast Excavator Bucket and Manufacturing Method Thereof," discloses an integrally cast excavator bucket having a lifting lug, a top plate, two side plates, and a bottom plate connected to the two side plates, wherein the lifting lug, the top plate, the two side plates, and the bottom plate are of an integral structure.

<CIT> discloses a bucket formed of a bucket section and a bracket member with the features of the preamble of present claim <NUM>. The bucket section is a welded structure composed of a bottom plate, right and left side plates, right and left side edges, a cutting edge, etc. The bracket member which is a single cast body is welded to the bottom plate of the bucket section, to thereby assemble the bucket. <CIT> discloses a casting process made of connection apparatus for construction equipment.

In accordance with the present disclosure there is provided an integrally cast hinge assembly for a bucket, an excavator bucket and a method in accordance with the claims.

Further features and advantages will be evident from the following illustrative embodiment which will now be described, purely by way of example and without limitation to the scope of the claims, and with reference to the accompanying drawings, in which:.

While the present disclosure describes certain embodiments of a bucket having a cast hinge assembly, the present disclosure is to be considered exemplary and is not intended to be limited to the disclosed embodiments. Also, certain elements or features of embodiments disclosed herein are not limited to a particular embodiment, but instead apply to all embodiments of the present disclosure.

The terminology as set forth herein is for description of the embodiments only and should not be construed as limiting the disclosure as a whole. All references to singular characteristics or limitations of the present disclosure shall include the corresponding plural characteristic or limitation, and vice versa, unless otherwise specified or clearly implied to the contrary by the context in which the reference is made. Unless otherwise specified, "a," "an," "the," and "at least one" are used interchangeably. Furthermore, as used in the description and the appended claims, the singular forms "a," "an," and "the" are inclusive of their plural forms, unless the context clearly indicates otherwise.

To the extent that the term "includes" or "including" is used in the description or the claims, it is intended to be inclusive in a manner similar to the term "comprising" as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term "or" is employed (e.g., A or B) it is intended to mean "A or B or both. " When the applicants intend to indicate "only A or B but not both" then the term "only A or B but not both" will be employed. Thus, use of the term "or" herein is the inclusive, and not the exclusive use. Furthermore, when the phrase "one or more of A and B" is employed it is intended to mean "only A, only B, or both A and B.

The bucket and hinge assembly of the present disclosure can comprise, consist of, or consist essentially of the essential elements of the disclosure as described herein, as well as any additional or optional element or feature described herein or which is otherwise useful in welding applications.

The term "about" as used herein, means approximately, in the region of, roughly, or around. When the term "about" is used in conjunction with a numerical value or range, it modifies that value or range by extending the boundaries above and below the numerical values set forth. In general, the term "about" is used herein to modify a numerical value above and below the stated value by <NUM>%.

All ranges and parameters, including but not limited to dimensions, percentages, and ratios, disclosed herein are understood to encompass any and all sub-ranges assumed and subsumed therein, and every number between the endpoints. For example, a stated range of "<NUM> to <NUM>" should be considered to include any and all sub-ranges beginning with a minimum value of <NUM> or more and ending with a maximum value of <NUM> or less (e.g., <NUM> to <NUM>, or <NUM> to <NUM>), and to each integer (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>) contained within the range.

<FIG> illustrate an exemplary embodiment of a bucket <NUM> according to the present disclosure, but not in accordance with the wording of the present claims. The bucket <NUM> may be a component of a machine (not shown). The machine may embody a mobile machine, such as an excavator or any other suitable machine, that may perform operations associated with an industry, including, for example, mining, construction, or farming. The machine may include a linkage assembly (not shown) coupled to the bucket <NUM>, including one or more supporting members and actuators for moving the bucket <NUM> to perform operations, including digging, scooping, lifting, and dumping material, such as earthen material.

The bucket <NUM> may include a top section <NUM>, a middle section <NUM>, and a bottom section <NUM>. The bucket <NUM> may include a first side plate <NUM> extending along the one side of the top section <NUM>, the middle section <NUM>, and the bottom section <NUM> and a second side plate <NUM> extending along the opposite side of the top section <NUM>, the middle section <NUM>, and the bottom section <NUM>. In the illustrated embodiment, the first side plate <NUM> is substantially a mirror image of the second side plate <NUM> and parallel to the second side plate <NUM>.

It should be noted that the terms upper, lower, top, bottom, forward, rear, as well as any other similar terms are used in reference to the position of the bucket <NUM> and hinge assembly as depicted in the figures and the bucket <NUM> and hinge assembly may be positioned and used in other orientations. Further, the terms front, forward, and other similar terms refer to the open end of the bucket <NUM> while the terms rear, rearward, and other similar terms refer to the opposite or closed end of the bucket <NUM>. In addition, the term laterally and other similar terms refers to the direction parallel to the width of the bucket <NUM> (i.e., the direction extending between the side plates <NUM>, <NUM>).

The top section <NUM> may include a support plate <NUM> (<FIG>) extending laterally between the first side plate <NUM> and the second side plate <NUM>. The middle section <NUM> may include a wrapper <NUM> extending between the first side plate <NUM> and the second side plate <NUM> from the top section <NUM> to the bottom section <NUM>. The wrapper <NUM> includes a first end <NUM> coupled to the support plate <NUM>, a second end <NUM> opposite the first end <NUM> and connected to a base edge <NUM> at the bottom section <NUM>, and a curved heel section <NUM> extending between first end <NUM> and the second end <NUM>.

The base edge <NUM> may be configured to engage and penetrate material. The bottom section <NUM> may also include one or more ground engaging tools <NUM>. The ground engaging tools <NUM> may be coupled to base edge <NUM>. The ground engaging tools <NUM> may include shrouds, teeth (adapters), top covers, half arrow segments, or any other tools, if desired.

The support plate may be welded to the first side plate <NUM>, the second side plate <NUM>, and the first end <NUM> of the wrapper <NUM>. Likewise, the wrapper <NUM> and the base edge <NUM> may be welded to each other and to the first side plate <NUM> and the second side plate <NUM>.

The top section <NUM> may also include a first torque tube portion <NUM> coupled to the support plate <NUM> adjacent the first side plate <NUM> and a second torque tube portion <NUM> coupled to the support plate <NUM> adjacent the first side plate <NUM> such that a gap <NUM> (<FIG>) exists between the first torque tube portion <NUM> and the second torque tube portion <NUM> that is configured to receive a hinge assembly <NUM>.

Referring to <FIG>, an exemplary embodiment of the hinge assembly <NUM> is illustrated. The hinge assembly <NUM> is manufactured through a casting process as an integral structure. Any suitable casting technique and suitable cast steel may be used. For example, in one exemplary embodiment, the hinge assembly <NUM> is manufactured through a sand casting process using an alloy steel.

The hinge assembly <NUM> may be configured in a variety of ways. Any configuration may be used that is capable of being formed as an integral structure through a casting process and capable of functioning as a hinge assembly for the bucket <NUM>.

In the illustrated embodiment, the hinge assembly <NUM> includes a first hinge plate <NUM> defining a first side <NUM> of the hinge assembly <NUM>, a second hinge plate <NUM> spaced apart from the first hinge plate <NUM> and defining a second side <NUM> of the hinge assembly <NUM>, and a third torque tube portion <NUM> extending between the first hinge plate <NUM> and the second hinge plate <NUM>.

In the illustrated embodiment, the first hinge plate <NUM> is parallel to and substantially the same as the second hinge plate <NUM>, but arranged in mirror image to the second hinge plate <NUM>. In other embodiments, however, the first hinge plate <NUM> and the second hinge plate <NUM> may be configured differently.

The first hinge plate <NUM> has a thickness T1 and includes a generally planar outer surface <NUM> and a generally planar inner surface <NUM> opposite the outer surface <NUM>. In the illustrated embodiment, the thickness T1 is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the thickness T1 may be greater than <NUM> or less than <NUM>.

The outer surface <NUM> and the inner surface <NUM> are connected by a front edge <NUM>, a rear edge <NUM> opposite the front edge <NUM>, a top edge <NUM> extending between the front edge <NUM> and the rear edge <NUM>, and a bottom edge <NUM> opposite the top edge <NUM> and extending between the front edge <NUM> and the rear edge <NUM>. The front edge <NUM> includes a linear section <NUM> that extends outward at a front angle µ relative to the bottom edge <NUM>. In the illustrated embodiment, the front angle µ is in the range of about <NUM> degrees to about <NUM> degrees, or in the range of about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees. In other embodiments, however, the front angle µ may be greater than <NUM> degrees or less than <NUM> degrees. Further, in other embodiments, the front edge <NUM> may not include a linear section. For example, the entire front edge <NUM> may be curved or otherwise nonlinear.

The front edge <NUM> transitions to the top edge <NUM> via a front curved portion <NUM>. In the illustrated embodiment, the front curved portion <NUM> has a radius RF in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In the illustrated embodiment, the top edge <NUM> includes an inward curved portion <NUM> having a center radius RTC in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, the radius RF may be greater than <NUM> or less than <NUM> and the center radius RTC may be greater than <NUM> or less than <NUM>. In some embodiments, the entire top edge <NUM> is curved inward. In other embodiments, however, only a portion of the top edge, such as a central portion, is curved inward. Still further, in some embodiments, the top edge <NUM> may be linear, outwardly curved, or any other suitable configuration.

The top edge <NUM> transitions to the rear edge <NUM> via a rear curved portion <NUM>. In the illustrated embodiment, the rear curved portion <NUM> has a radius RR in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In the illustrated embodiment, the rear edge <NUM> includes an inward curved portion <NUM> having a center radius RRC in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the radius RR may be greater than <NUM> or less than <NUM> and the center radius RRC may be greater than <NUM> or less than <NUM>. In some embodiments, the entire rear edge <NUM> is curved inward. In other embodiments, however, only a portion of the rear edge <NUM>, such as a central portion, is curved inward. Still further, in other embodiments, the rear edge <NUM> may be linear, outward curved, or any other suitable configuration.

The bottom edge <NUM> is configured to mount onto, or be complimentary to, the support plate <NUM>. In the illustrated embodiment, the bottom edge <NUM> includes a first linear portion <NUM> adjacent the rear edge <NUM>, a second linear portion <NUM> adjacent the front edge <NUM>, and a rearward facing shoulder <NUM> connecting the first linear portion <NUM> to the second linear portion <NUM>. In the illustrated embodiment, the first linear portion <NUM> has a length LL in the range about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the length LL may be greater than <NUM> or less than <NUM>.

The first hinge plate <NUM> further includes a front pin bore <NUM> positioned adjacent the front curved portion <NUM> and extending along a front axis A, and a rear pin bore <NUM> positioned adjacent the rear curved portion <NUM> and extending along a rear axis B. In the illustrated embodiments, the front pin bore <NUM> is concentric with the front curved portion <NUM> and the rear pin bore <NUM> is concentric with the rear curved portion <NUM>. In other embodiments, however, the front pin bore <NUM> and the rear pin bore <NUM> may not be concentric with the front curved portion <NUM> and the rear curved portion <NUM>, respectively.

The first hinge plate <NUM> also includes a front outer boss <NUM>, circumscribing the front pin bore <NUM> and extending from the outer surface <NUM> of the first hinge plate <NUM>. In the illustrated embodiment, the front outer boss <NUM> has a thickness T2, a cylindrical outer side surface <NUM>, and a planar outer face <NUM> that is parallel to the outer surface <NUM>. The first hinge plate <NUM> further includes a rear outer boss <NUM>, circumscribing the rear pin bore <NUM> and extending from the outer surface <NUM> of the first hinge plate <NUM>. In the illustrated embodiment, the rear outer boss <NUM> has a thickness T3, a cylindrical outer side surface <NUM>, and a planar outer face <NUM> that is parallel to the outer surface <NUM>. In the illustrated embodiment, the front outer boss thickness T2 equals the rear outer boss thickness T3 and the planar outer face <NUM> of the rear outer boss <NUM> is coplanar with the planar outer face <NUM> of the front outer boss <NUM>. In an exemplary embodiment, the rear outer boss thickness T3 is in the range of about <NUM> to about <NUM>, or in the range of <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the rear outer boss thickness T3 may be greater than <NUM>.

The first hinge plate <NUM> further includes a front inner boss <NUM>, circumscribing the front pin bore <NUM>, and extending from the inner surface <NUM> of the first hinge plate <NUM>. In the illustrated embodiment, the front inner boss <NUM> has a thickness T4, a first chamfered section <NUM>, and a second chamfered section <NUM> separated from the first chamfered section <NUM> by a radial shoulder section <NUM>. The second chamfered section <NUM> tapers at an angle β relative to the inner surface <NUM>. In the exemplary embodiment, the angle β is in the range of about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees. In the illustrated embodiment, the first inward chamfered section <NUM> extends at the same angle relative to the inner surface <NUM> as the second inward chamfered section <NUM>. In other embodiments, however, the first inward chamfered section <NUM> may extends at a different angle relative to the inner surface <NUM> than second inward chamfered section <NUM>. In an exemplary embodiment, the thickness T4 is in the range of about <NUM> to about <NUM>, or in the range of <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the rear outer boss thickness T3 may be greater than <NUM>.

The first hinge plate <NUM> further includes a rear inner boss <NUM>, circumscribing the rear pin bore <NUM>, and extending from the inner surface <NUM> of the first hinge plate <NUM>. In the illustrated embodiment, the rear inner boss <NUM> has a thickness T5, a first inward chamfered section <NUM> and a second inward chamfered section <NUM> separated from the first inward chamfered section <NUM> by a radial shoulder section <NUM>. The second inward chamfered section <NUM> tapers at an angle α relative to the inner surface <NUM>. In the exemplary embodiment, the angle α is the same as the angle β. In the illustrated embodiment, the first inward chamfered section <NUM> extends at the same angle relative to the inner surface <NUM> as the second inward chamfered section <NUM>. In other embodiments, however, the first inward chamfered section <NUM> may extends at a different angle relative to the inner surface <NUM> than second inward chamfered section <NUM>.

As shown in <FIG>, the first hinge plate <NUM> has a front height HF and a rear height HR. In the exemplary embodiment, the front height HF is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM> and the rear height is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the front height HF may be greater than <NUM> or less than <NUM> and the rear height HR may be greater than <NUM> or less than <NUM>.

The first hinge plate <NUM> has a front pin bore height HFP, as measured from the pin bore center (indicated as axis A in <FIG>) to the first linear portion <NUM> of the bottom edge <NUM>, and a rear pin bore height HRP, as measured from the rear pin bore center (indicated as axis B in <FIG>) to the first linear portion <NUM> of the bottom edge <NUM>. In the illustrated embodiment, the front pin bore height HFP is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>, and the rear pin bore height HRP is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the front pin bore height HFP may be greater than <NUM> or less than <NUM> and the rear pin bore height HRP may be greater than <NUM> or less than <NUM>. The ratio of front pin bore height HFP to rear pin bore height HRP (HFP:HRP) is in the range of about <NUM> to <NUM>, or about <NUM>.

The center of the front pin bore <NUM> (indicated as axis A in <FIG>) is a distance D1 from the center of the rear pin bore <NUM> (indicated as axis B in <FIG>). In the illustrated embodiment, the distance D1 is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the distance D1 may be greater than <NUM> or less than <NUM>.

The first hinge plate <NUM> has a bottom length LB and a top length LT. In the illustrated embodiment, the bottom length LB is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>, and the top length LT is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the bottom length LB may be greater than <NUM> or less than <NUM> and the top length LT may be greater than <NUM> or less than <NUM>.

As indicated earlier, in the illustrated embodiment, the second hinge plate <NUM> is substantially similar to the first hinge plate <NUM>. Thus, the description of the first hinge plate <NUM> applies equally to the second hinge plate <NUM>. For example, the second hinge plate <NUM> includes a generally planar outer surface <NUM>, a generally inner surface <NUM>, a front edge <NUM>, a rear edge <NUM>, a top edge <NUM>, a bottom edge <NUM> having a rearward facing shoulder <NUM>, a front pin bore <NUM>, rear pin bore <NUM>, a front outer boss <NUM>, a rear outer boss <NUM>, a front inner boss <NUM>, and a rear inner boss <NUM>.

As shown in <FIG>, the hinge assembly <NUM> has an inside width WI measured from the front inner boss <NUM> on the first hinge plate <NUM> to the front inner boss <NUM> on the second hinge plate <NUM>. The hinge assembly <NUM> also has an outside width WO measured from the front outer boss <NUM> on the first hinge plate <NUM> to the front outer boss <NUM> on the second hinge plate <NUM>. In the illustrated embodiment the inside width WI is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>, and the outside width WO is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the inside width WI may be greater than <NUM> or less than <NUM> and the outside width WO may be greater than <NUM> or less than <NUM>.

As shown in <FIG>, the third torque tube portion <NUM> has a top surface <NUM>, a bottom surface <NUM> generally parallel to and opposite the top surface <NUM>, and a thickness T6. The third torque tube portion <NUM> includes a first planar portion <NUM> extending upward at an angle θ relative to the bottom edge <NUM>, a second planar portion <NUM> extending perpendicular, or about perpendicular, to the bottom edge <NUM>, and a curved portion <NUM> connecting the first planar portion <NUM> to the second planar portion <NUM>. In the illustrated embodiment, the thickness T6 is in the range about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>, and the angle θ is in the range of about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees. The curved portion <NUM> has an inner radius RTT in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the thickness T6 may be greater than <NUM> or less than <NUM>, the angle θ may be greater than <NUM> degrees or less than <NUM> degrees, and the inner radius RTT may be greater than <NUM> or less than <NUM>.

The third torque tube <NUM> has a height HT measured from the bottom edge <NUM> to the uppermost portion of the top surface <NUM> of the curved portion <NUM> and a length LA measured along the bottom edge <NUM> between the inside surfaces <NUM> of the first planar portion <NUM> and the second planar portion <NUM>. In the exemplary embodiment, the height HT is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>, and the length LA is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the height HT may be less than <NUM> or greater than <NUM> and the length LA may be less than <NUM> or greater than <NUM>. The third torque tube <NUM> has a cross-section area AC measured by a multiplying the total height HT by the inside length LA. In the exemplary embodiment, the cross section area AC is in the range of about <NUM><NUM> to about <NUM><NUM>, or about <NUM><NUM>.

As shown in the <FIG>, <FIG>, and <FIG>, for example, the top surface <NUM> and the bottom surface <NUM> of the third torque tube portion <NUM> transitions to the inner surface <NUM> of the first hinge plate <NUM> and the inner surface <NUM> of the second hinge plate <NUM>, respectively, by curved or radiused intersections CI. These curved or radiused intersections CI provide for the transfer of load gradually into the surrounding structure of the hinge assembly <NUM> and bucket <NUM>. In addition, as shown in <FIG>, the corners where the third torque tube <NUM> intersects the first and second hinge plates <NUM>, <NUM> are thicker (i.e., include additional material) as compared to the third torque tub thickness to improve the structural strength of the hinge assembly <NUM>.

<FIG> illustrates an exemplary embodiment of a bucket <NUM> according to the present invention. The bucket <NUM> is similar to the bucket <NUM> of <FIG> in that the bucket <NUM> may include a top section <NUM>, a middle section <NUM>, and a bottom section <NUM>. The bucket <NUM> may include a first side plate <NUM> extending along the one side of the top section <NUM>, the middle section <NUM>, and the bottom section <NUM>, and a second side plate <NUM> extending along the opposite side of the top section <NUM>, the middle section <NUM>, and the bottom section <NUM>. In the illustrated embodiment, the first side plate <NUM> is substantially a mirror image of the second side plate <NUM> and parallel to the second side plate <NUM>.

The middle section <NUM> may include a wrapper <NUM> extending between the first side plate <NUM> and the second side plate <NUM> from the top section <NUM> to the bottom section <NUM>. The wrapper <NUM> includes a first end <NUM>, a second end <NUM> opposite the first end <NUM>, and a curved heel section <NUM> extending between first end <NUM> and the second end <NUM>. The second end <NUM> is connected to a base edge <NUM> at the bottom section <NUM>.

The base edge <NUM> may be configured to engage and penetrate material. The bottom section <NUM> may also include one or more ground engaging tools <NUM>. The ground engaging tools <NUM> may be coupled to the base edge <NUM>. It is contemplated that, in other embodiments, the ground engaging tools <NUM> may include shrouds, teeth (adapters), top covers, half arrow segments, or any other tools, if desired.

The wrapper <NUM> and the base edge <NUM> may be welded to each other and to the first side plate <NUM> and the second side plate <NUM>. The top section <NUM> may be formed by a hinge assembly <NUM>.

Referring to <FIG>, an exemplary embodiment of the hinge assembly <NUM> is illustrated. As with the hinge assembly <NUM> of <FIG>, the hinge assembly <NUM> is manufactured through a casting process as an integral structure. The hinge assembly <NUM> may be configured in a variety of ways. Any configuration may be used that is capable of being formed as an integral structure through a casting process and capable of functioning as a hinge assembly for the bucket <NUM>.

In the illustrated embodiment, the hinge assembly <NUM> may include a support plate <NUM>, a first torque tube portion <NUM> adjacent the first side plate <NUM>, a second torque tube portion <NUM> adjacent the second side plate <NUM>, a first hinge plate <NUM> adjacent the first torque tube portion <NUM>, a second hinge plate <NUM> adjacent the second torque tube portion <NUM>, and a third torque tube portion <NUM> extending between the first hinge plate <NUM> and the second hinge plate <NUM>. Thus, while the hinge assembly <NUM> of <FIG> is configured to be attached to the support plate <NUM>, the first torque tube portion <NUM>, and the second torque tube portion <NUM>, such as for example by welding, the hinge assembly <NUM> includes the support plate <NUM>, the first torque tube portion <NUM>, and the second torque tube portion <NUM> as part of the cast, integral structure of the hinge assembly <NUM>. In other embodiments, however, the hinge assembly <NUM> may be configured similar to the hinge assembly <NUM> and include a first hinge plate, a second hinge plate, and a third torque tube portion that are configured to be welded to the support plate <NUM>, the first torque tube portion <NUM>, and the second torque tube portion <NUM>.

In the illustrated embodiment, the first hinge plate <NUM> is parallel to and substantially the same as the second hinge plate <NUM>, but arranged in mirror image to the second hinge plate <NUM>. In other embodiments, however, the first hinge plate <NUM> and the second hinge plate <NUM> may differ. The first hinge plate <NUM> includes an outer surface <NUM>, an inner surface <NUM> opposite the outer surface <NUM>, and a thickness T1. In the illustrated embodiment, the thickness T1 is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the thickness T1 may be greater than <NUM> or less than <NUM>.

The outer surface <NUM> and the inner surface <NUM> are connected by a front edge <NUM>, a rear edge <NUM> opposite the front edge <NUM>, and a top edge <NUM> extending between the front edge <NUM> and the rear edge <NUM>. The front edge <NUM> includes a linear section <NUM> that extends outward at a front angle µ relative to the support plate <NUM>. In the illustrated embodiment, the front angle µ is in the range of about <NUM> degrees to about <NUM> degrees, or in the range of about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees. In other embodiments, however, the front angle µ may be less than <NUM> degrees or greater than <NUM> degrees. In some embodiments, the front edge <NUM> may not include a linear section. For example, the entire front edge <NUM> may be curved or otherwise nonlinear.

The front edge <NUM> transitions to the top edge <NUM> via a front curved portion <NUM>. In the illustrated embodiment, the front curved portion <NUM> has a radius RF in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In the illustrated embodiment, the top edge <NUM> includes an inward curved portion <NUM> having a center radius RTC in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the radius RF may be less than <NUM> or greater than <NUM> and the center radius RTC may be less than <NUM> or greater than <NUM>. In some embodiments, the entire top edge <NUM> is curved inward. In other embodiments, however, only a portion of the top edge <NUM>, such as a central portion, is curved inward. Still further, in other embodiments, the top edge <NUM> may be linear, outward curved, or any other suitable configuration.

The top edge <NUM> transitions to the rear edge <NUM> via a rear curved portion <NUM>. In the illustrated embodiment, the rear curved portion <NUM> has a radius RR in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In the illustrated embodiment, the rear edge <NUM> includes a linear portion <NUM> that extends at a rear angle σ relative to the support plate <NUM>. In the illustrated embodiment, the rear angle σ is in the range of about <NUM> degrees to about <NUM> degrees, or in the range of about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees. In other embodiments, however, the radius RR may be less than <NUM> or greater than <NUM> and the rear angle σ may be less than <NUM> degrees or greater than <NUM> degrees. In other embodiments, the rear edge <NUM> may not include a linear section. For example, the entire rear edge <NUM> may be curved or otherwise nonlinear.

The rear edge <NUM> transitions to the support plate <NUM> via an inward curved portion <NUM> and a rearward facing shoulder <NUM>. The inward curved portion <NUM> and rearward facing shoulder <NUM> are configured to provide a smooth stress transition through the structure of the hinge assembly <NUM>.

The first hinge plate <NUM> includes a rear outer boss <NUM>, circumscribing the rear pin bore <NUM>, and extending from the outer surface <NUM> of the first hinge plate <NUM>. In the illustrated embodiment, the first hinge plate <NUM> does not include a front outer boss circumscribing the front pin bore <NUM>. In various embodiments, the presence of an inner or an outer boss, whether front or rear, may depend on the particular linkage of the machine to which the hinge assembly will attach and to the pins used to attach the hinge assembly to the linkage.

The first hinge plate <NUM> further includes a front inner boss <NUM> circumscribing the front pin bore <NUM> and extending from the inner surface <NUM> of the first hinge plate <NUM>. The first hinge plate <NUM> further includes a rear inner boss <NUM>, circumscribing the rear pin bore <NUM>, and extending from the inner surface <NUM> of the first hinge plate <NUM>.

In the illustrated embodiment, the second hinge plate <NUM> is substantially similar to the first hinge plate <NUM>. Thus, the description of the first hinge plate <NUM> applies equally to the second hinge plate <NUM>. For example, the second hinge plate <NUM> includes an outer surface <NUM>, an inner surface <NUM>, a front edge <NUM>, a rear edge <NUM> that transition to the support plate <NUM> via a rearward facing shoulder <NUM>, a top edge <NUM>, a front pin bore <NUM>, rear pin bore <NUM>, a front outer boss <NUM>, a rear outer boss <NUM>, a front inner boss <NUM>, and a rear inner boss <NUM>.

As shown in <FIG>, the first hinge plate <NUM> has a front height HF and a rear height HR. In the exemplary embodiment, the front height HF is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM> and the rear height HR is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the front height HF may be greater than <NUM> or less than <NUM> and the rear height HR may be greater than <NUM> or less than <NUM>.

The first hinge plate <NUM> has a front pin bore height HFP, as measured from the pin bore center (indicated as axis A in <FIG>) to the support plate <NUM>, and a rear pin bore height HRP, as measured from the rear pin bore center (indicated as axis B in <FIG>) to the support plate <NUM>. In the illustrated embodiment, the front pin bore height HFP is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM> and the rear pin bore height HRP is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the front pin bore height HFP may be greater than <NUM> or less than <NUM> and the rear pin bore height HRP may be greater than <NUM> or less than <NUM>.

The first hinge plate <NUM> has total length LT measured from the forwardmost portion of the front curved portion <NUM> to the rearward most portion of the support plate <NUM>. In the illustrated embodiment, the total length LT is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the total length LT may be greater than <NUM> or less than about <NUM>.

As shown in <FIG>, the hinge assembly <NUM> has an inside width WI measured from the rear inner boss <NUM> on the first hinge plate <NUM> to the rear inner boss <NUM> on the second hinge plate <NUM>. The hinge assembly <NUM> also has an outside width WO measured from the rear outer boss <NUM> on the first hinge plate <NUM> to the rear outer boss <NUM> on the second hinge plate <NUM>. In the illustrated embodiment the inside width WI is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>, and the outside width WO is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the inside width WI may be greater than <NUM> or less than <NUM> and the outside width WO may be greater than <NUM> or less than <NUM>.

As shown in <FIG>, the third torque tube portion <NUM> has an outer surface <NUM>, an inner surface <NUM> generally parallel to and opposite the outer surface <NUM>, and a thickness T6. The third torque tube portion <NUM> includes a first planar portion <NUM> extending upward at an angle θ relative to the support plate <NUM>, and a second planar portion <NUM> extending forward at an obtuse angle α relative to the support plate <NUM>. In the illustrated embodiment, the thickness T6 is in the range about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>, the angle θ is in the range of about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees, and the angle α is in the range of about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees. In other embodiments, however, the thickness T6 may be less than <NUM> or greater than <NUM>, the angle θ may be less than <NUM> degrees or greater than <NUM> degrees, and the angle α may be less than <NUM> degrees or greater than <NUM> degrees.

The third torque tube portion <NUM> includes a third planar portion <NUM> connecting the first planar portion <NUM> to the second planar portion <NUM>. The first planar portion <NUM> transitions to the third planar portion <NUM> by a first curved portion <NUM> having a first inner radius R1 and the second planar portion <NUM> transitions to the third planar portion <NUM> by a second curved portion <NUM> having a second inner radius R2. In the illustrated embodiment the first inner radius R1 is equal to the second inner radius R2. In other embodiments, however, the first inner radius R1 may differ from the second inner radius R2. In the illustrated embodiment, the first inner radius R1 is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the first inner radius R1 may be less than <NUM> or greater than <NUM>.

The third torque tube <NUM> has a height HT measured from a bottom surface <NUM> of the support plate <NUM> to the uppermost portion of the outer surface <NUM> of the first curved portion <NUM> and a length LA measured along the upper surface <NUM> of the support plate <NUM> between the inside surfaces <NUM> of the first planar portion <NUM> and a second planar portion <NUM>. In the exemplary embodiment, the height HT is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>, and the length LA is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the height HT may be less than <NUM> or greater than <NUM> and the length LA may be less than <NUM> or greater than <NUM>. The third torque tube <NUM> has a cross-section area AC measured by a multiplying the total height HT by the length LA. In the exemplary embodiment, the cross section area AC is in the range of about <NUM><NUM> to about <NUM><NUM>, or about <NUM><NUM>.

The support plate <NUM> is configured to mount to the first end <NUM> of the wrapper <NUM> and to the side plates <NUM>, <NUM>. In the illustrated embodiment, the support plate <NUM> has an upper surface <NUM>, a lower surface <NUM> parallel to and opposite the upper surface <NUM>, a first side edge <NUM> extending between the upper surface <NUM> and the lower surface <NUM>, a second side edge <NUM> opposite the first side edge <NUM> and extending between the upper surface <NUM> and the lower surface <NUM>, and a rear edge <NUM> extending between the first side edge <NUM> and the second side edge <NUM>.

As shown in <FIG>, the support plate <NUM> serves as the bottom portion of the first, second, and third torque tube portions <NUM>, <NUM>, <NUM>. Thus, the upper surface <NUM> of the support plate <NUM> is an inner surface within the torque tube portions <NUM>, <NUM>, <NUM>. The first planar portion <NUM> transitions into the support plate <NUM> via a third curved portion <NUM> having an outer radius R3. In the illustrated embodiment, the outer radius R3 is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. The second planar portion <NUM> transitions into the support plate <NUM> via a fourth curved portion <NUM> having an inner radius R4 in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the outer radius R3 may be less than <NUM> or greater than <NUM>, and the inner radius R4 may be less than <NUM> or greater than <NUM>.

As shown in <FIG>, the support plate <NUM> along with the planar portion <NUM>, <NUM>, <NUM> and curved portions <NUM>, <NUM>, <NUM>, <NUM> of the torque tubes portions <NUM>, <NUM>, <NUM> form a closed, diamond-like opening <NUM> through the torque tube portions <NUM>, <NUM>, <NUM>. In the illustrated embodiment, the first torque tube portion <NUM> and the second torque tube portion <NUM> are configured substantially the same as the third torque tube portion <NUM>.

Referring to <FIG>, the hinge assembly <NUM> has a total width WT, the first torque tube portion <NUM> has a first width W1, and the second torque tube portion <NUM> has a second width W2. In the illustrated embodiment, the first width W1 is equal to the second width W2. In other embodiments, however, the first width W1 may be different than the second width W2. In the illustrated embodiment, the total width WT is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM> and, the first width W1 is in the range of about <NUM> to about <NUM>, or in the range of about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, total width WT may be less than <NUM> or greater than <NUM>, and the first width W1 may be less than <NUM> or greater than <NUM>.

Referring to <FIG>, the hinge assembly <NUM> includes a first inner rib <NUM> and a second inner rib <NUM>. The first inner rib <NUM> is aligned with the first hinge plate <NUM> and extends inward from the inner surface <NUM> at an intersection between the first torque tube portion <NUM> and the third torque tube portion <NUM>. The second inner rib <NUM> is aligned with the first hinge plate <NUM> and extends inward from the inner surface <NUM> at an intersection between the second torque tube portion <NUM> and the third torque tube portion <NUM>. In the illustrated embodiment, the first inner rib <NUM> is identical to the second inner rib <NUM>, thus, the description of the first inner rib <NUM> applies equally to the second inner rib <NUM>. In other embodiments, however, the first inner rib <NUM> may not be identical to the second inner rib <NUM>.

The first inner rib <NUM> may be configured in a variety of ways. In the illustrated embodiment, the first inner rib <NUM> is continuous and extends around the entire periphery of the opening <NUM>. In other embodiments, the first inner rib <NUM> may not extend around the entire periphery of the opening <NUM>. The first inner rib <NUM> includes a lower portion <NUM> having a first width WR1 and an upper portion <NUM> having a second width WR2 that is greater than the first width WR1. In the exemplary embodiment, the first width WR1 is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>, and the second width WR2 is in the range of about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. In other embodiments, however, the first width WR1 may be less than <NUM> or greater than <NUM>, and the second width WR2 may be less than <NUM> or greater than <NUM>.

As shown in <FIG>, the width of the first inner rib <NUM> tapers inward from the lower portion <NUM> to the upper portion <NUM> along the inner surface <NUM>. The first inner rib <NUM> transitions to the inner surface <NUM> and the upper surface <NUM> via a curved or radiused intersection <NUM> around both the interface between the first inner rib <NUM> and the first torque tube portion <NUM> and the interface between the first inner rib <NUM> and the third torque tube portion <NUM>. Likewise, the second inner rib <NUM> transitions to the inner surface <NUM> and the upper surface <NUM> via a or radiused intersection <NUM> around both the interface between the second inner rib <NUM> and the second torque tube portion <NUM> and the interface between the second inner rib <NUM> and the third torque tube portion <NUM>.

As shown in the <FIG>, for example, the outer surface <NUM> of the third torque tube portion <NUM> transitions to the inner surfaces <NUM> of the first hinge plate <NUM> and the inner surface <NUM> of the second hinge plate <NUM> by curved or radiused intersections CI. Likewise, the outer surface of the first torque tube portion <NUM> transitions to the outer surface <NUM> of the first hinge plate <NUM> by curved or radiused intersections CI and the outer surface of the second torque tube portion <NUM> transitions to the outer surface <NUM> of the second hinge plate <NUM> by curved or radiused intersections CI. These curved or radiused intersections CI provide for the transfer of load gradually into the surrounding structure of the hinge assembly <NUM> and bucket <NUM>.

Table <NUM> indicates dimensions for three exemplary embodiments of hinge assemblies according to the present disclosure. Embodiment A is an example of the hinge assembly <NUM> of <FIG>, Embodiment B is an example of the hinge assembly <NUM> of <FIG>, and Embodiment C is an example of a smaller hinge assembly according to the present disclosure. All numbers expressed in Table <NUM> are to be understood as being modified in all instances by the term "about.

As shown in the table, hinge assemblies according to the present disclosure are contemplated as having a variety of sizes and shapes. For example, for a given dimension, the value may range from the smaller size of Embodiment C to the larger size of Embodiment B, and any value in between. The front radius RF of the hinge assembly, for example, may be in the range of about <NUM> to about <NUM>, and so forth for the other parameters listed. The column containing the ratio B/C for each dimension, illustrates the ratio between the dimension on the smaller hinge assembly as compared to the dimension on the larger hinge assembly. As shown in the table, the ratio may differ for different parameters, but it typically in the range of about <NUM> to about <NUM>. In other embodiments, however, a hinge assembly according to the present disclosure may one or more dimensions which have values larger than those shown for Embodiment B or smaller than those shown for Embodiment C.

While the exemplary embodiments of the novel hinge assemblies <NUM>, <NUM> are illustrated as used in excavator buckets, the hinge assemblies may be used in other bucket applications, such as wheel loaders, backhoes, or other earth moving equipment. The hinge assemblies <NUM>, <NUM> are configured with features that provide improved life/durability and increases hinge strength as compared to conventional welded hinge plate designs. For example, the hinge assemblies may include additional material at key locations, such as around the hinge bosses and at the interfaces between the torque tube portions and hinge plates.

Further, the overall shape of the hinge assembly results in improved life of the bucket and provides for the transfer of load gradually into the surrounding structure of the hinge assembly and bucket to improve the life of the bucket welds and reduce machine downtime due to maintenance. For example, for the hinge assembly <NUM>, the hinge plates are weldlessly connected to the central torque tube portion (i.e., not connected via welds) and the front and rear bosses (both inner and outer) on both the first and second hinge plates are weldlessly connected to the respective hinge plate. In addition, in most the instances, when two surfaces intersect on the hinge assembly, the intersection is a radiused or curved intersection. For example, the intersection between the outer surface of the first hinge plate and the cylindrical outer side surface of the front outer boss is curved, as is the intersection between the upper surface of one or more of the torque tube portions and each of the hinge plates. Further, the hinge assembly includes relatively large radiuses around the pin bores which results in lower stress and better fatigue life.

In addition to the improved performance of the hinge assemblies, the casting the hinge assemblies as an integral structure, as opposed to forming the hinge assemblies from a plurality of welded-together pieces, makes manufacturing the bucket simpler and less time consuming. For example, <FIG> illustrates an exemplary embodiment of a process <NUM> for manufacturing the bucket <NUM> of <FIG>. In step <NUM>, a first side plate is welded to a first side edge of a wrapper. In step <NUM>, a second side plate is welded to a second side edge of the wrapper. In step <NUM>, a support plate is welded to an upper edge of the wrapper and to each of the first and second side plates. In step <NUM>, a first torque tube portion is welded to the support plate and the first side plate. In step <NUM>, a second torque tube portion is welded to the support plate and the second side plate such that a gap is formed between the first and second torque tube portions. In step <NUM>, a cast hinge assembly is provided including a first hinge plate and second hinge plate and a third torque tube portion as an integral, weldless structure. In step <NUM>, the cast hinge assembly is positioned with in the gap and welded to the support plate, the first torque tube portion, and the second torque tube portion.

Referring to <FIG>, an exemplary embodiment of a process <NUM> for manufacturing the bucket <NUM> of <FIG> is illustrated. In step <NUM>, a first side plate is welded to a first side edge of a wrapper. In step <NUM>, a second side plate is welded to a second side edge of the wrapper. In step <NUM>, a cast hinge assembly is provided having a width and including a first hinge plate, a second hinge plate, a support plate, a first torque tube portion, a second torque tube portion, and a third torque tube portion formed as an integral, weldless structure. In step <NUM>, if required, the first torque tube portion and/or the second torque tube portion are cut such that the width of the cast hinge assembly fits between, and spans the distance between, the first side plate and the second side plate. In step <NUM>, the cast hinge assembly is positioned between, and welded to, the first hinge plate and the second hinge plate.

Claim 1:
An integrally cast hinge assembly (<NUM>) for a bucket (<NUM>), comprising:
a first hinge plate (<NUM>) having a first outer side surface (<NUM>) and a first inner side surface (<NUM>);
a first torque tube portion (<NUM>) extending from the first outer side surface (<NUM>);
a second hinge plate (<NUM>) spaced apart from the first hinge plate (<NUM>), the second hinge plate (<NUM>) having a second outer side surface (<NUM>) and a second inner side surface (<NUM>);
a second torque tube portion (<NUM>) extending from the second outer side surface (<NUM>);
a third torque tube portion (<NUM>) extending from the first inner side surface (<NUM>) and the second inner side surface (<NUM>) to span between the first hinge plate (<NUM>) and the second hinge plate (<NUM>); and
a support plate (<NUM>) extending along a bottom portion of the hinge assembly (<NUM>);
wherein the first torque tube portion (<NUM>) is weldlessly connected to the first hinge plate (<NUM>), the second torque tube portion (<NUM>) is weldlessly connected to the second hinge plate (<NUM>), the third torque tube portion (<NUM>) is weldlessly connected to both the first hinge plate (<NUM>) and the second hinge plate (<NUM>), and the support plate (<NUM>) is weldlessly connected to the first hinge plate (<NUM>), the second hinge plate (<NUM>), the first torque tube portion (<NUM>), the second torque tube portion (<NUM>), and the third torque tube portion (<NUM>);
characterised by the hinge assembly (<NUM>) further comprising a first inner rib (<NUM>) aligned with the first hinge plate (<NUM>) and extending inward at an intersection between the first torque tube portion (<NUM>) and the third torque tube portion (<NUM>).