GB2487609A

GB2487609A - Curved Wire Basket

Info

Publication number: GB2487609A
Application number: GB201110002A
Authority: GB
Inventors: David Snell
Original assignee: CAMERON ROBB Ltd; FORMBAR Ltd
Current assignee: CAMERON ROBB Ltd; FORMBAR Ltd
Priority date: 2010-12-10
Filing date: 2011-06-14
Publication date: 2012-08-01
Anticipated expiration: 2031-06-14
Also published as: GB201110002D0; GB2487609B; CN102602579B; GB201020904D0; CN102602579A

Abstract

A curved wire basket having a wire lattice base comprising two sets of parallel wires at an angle to one another to form the base lattice, and having a side wall with a curved portion, the wires proximate the curved portion 74 being angled to extend directly towards the perimeter of the base i.e. extending along the radius of the curve to avoid large gaps in the mesh. The basket is made by placing the first and second sets of straight wires on top of one another in a former or mould on top of a peripheral wire (49, Figure 6) and soldering them together. The wires are fastened together e.g. by welding to form a uniform mesh section. Wires having bent ends are welded to the mesh proximate the curved wall portion. The ends of the wires extending from the base are bent upwards to form the sidewalls and attached to a top frame (43, Figure 6) Wire bands (45-48, Figure 6) may be placed around the basket and welded thereto. The lattice may comprise square, rectangle or diamond shapes.

Description

A METHOD OF MANUFACTURING A BASKET

FIELD OF INVENTION

The present invention relates to a method of manufacturing wire lattice baskets and the like as used by shops for hand-held baskets and for wheeled trolleys. In particular the present invention relates to a method of making baskets having a base and a curved sidewall.

BACKGROUND TO THE INVENTION

Baskets have been known and made throughout the ages for a multitude of uses. The first baskets were manufactured form plant Is materials such as wicker, willow, palm leaves and the like and have been of various shapes and sizes. For shopping, especially in "developed" countries baskets would be used in preference to bags since the weight of any contents would not cause a middle part of a base of the bag to sink, causing the contents to bear against each other, which when they were perishable or otherwise soft, could get damaged by other goods. Indeed, bottles, jugs and similar containers for fluids would need a generally level base upon which they were supported or otherwise be liable to spill their contents, especially if not well capped. Until the early nineteen twenties, none but variants of the wicker-style baskets existed. As shops became increasingly competitive, especially with the rise of the so-called supermarkets in the nineteen thirties, shops started to provide baskets of wire, which were always of a rectangular construction, generally with a reducing circumference toward a base whereby to enable stacking.

The sizes of baskets increased so that shoppers could purchase more -but it was then realised that the weight of the baskets, with contents could then become overbearing. In order to allow customers to shop for longer, wheeled baskets or shopping trolleys were developed, again with a generally rectangular shape -this is because shoppers would tire of supporting a basket for tens of minutes at a time. In order to be stored using a minimum ground area, the trolleys were developed so that they could be staked-albeit in a horizontal fashion. Indeed, the trolleys were manufactured so that their plan was in the shape of an Isosceles trapezium, whereby the front of one trolley would fit within another, entering through a rear wall, when the rear wall of the trolley would pivot upwardly or otherwise move to enable such stacking or telescoping.

Despite the popularity of shopping trolleys and shopping baskets comprised of wire lattice, they have generally been of an overall rectangular shape as discussed above; limited numbers of circular baskets have been produced but such baskets have been made with radially extending wires from a central clamp and have not been utilised to any substantial degree in commerce. Figure 3 shows one type of wire basket -from UCA255576 (Fuller) which shows a basket with a large central hole in a base portion, otherwise arranged with wires extending from the large central hole. Simple variations of angular Baskets have been manufactured generally of an overall rectangular shape as a result of the need to make baskets at a competitive price, to be easily and reliably produced, to have a minimal weight, and, most importantly be of a design whereby they retain the contents within the basket, that is to say, were there to be a curve in a sidewall, then dependent upon the spacing between adjacent parallel lattice wire, then there was an increased likelihood of items that were placed within the basket from falling out.

OBJECT TO THE INVENTION

The present invention seeks to provide an improved basket formed from a wire lattice. In particular, the present invention seeks to provide a solution to the problems addressed above. The present invention further seeks to provide a method of manufacturing a basket whereby non-rectilinear designs of basket can be fabricated easily and reliably and that and functional shapes can be created whilst maintaining contents securely.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided a method of manufacturing a wire lattice basket, the basket comprising a base and sidewall, the base having one or more arcuate perimeter sections extending over a plurality of lattice sections and a sidewall depending upwardly from the base perimeter, said base lattice being defined by first and second sets of parallel wires being arranged in layers one with respect to the other, the first and second sets of wires being angularly disposed in the range of 60° -90°, the wires from the base extending upwardly from the sidewall to a top rim, with a number of wires being arranged about the sides of the basket; the method comprising at least the following steps: arranging straight elongate rectilinear wires in a parallel fashion along first and second axes, said first and second axes being arranged to provide a lattice base for the basket; arranging along an arcuate perimeter edge section a wire that has been bent between the lattice and the perimeter of the base, whereby to have a distal end of the wire at the perimeter spaced substantially equidistant with respect to distal ends of the wires adjacent wires at the perimeter; fastening the lattice wires together; bending the wires extending from the base about 75 -go direction whereby to define a general basket shape; fastening a top rim to the upstanding wires; and fastening one or more rim wires about the sides of the basket.

The product thereby simply created in a minimum of production steps provides a simple manner of providing a lattice basket with an arcuate shape where any gap defined at a perimeter edge between a base and a sidewall is minimised.

Conveniently the method also includes the step of attaching a base rim wire on or about the base, whereby to increase the structural Is integrity of the base. This rim wire can be fastened either internally or externally to the basket. Handles can conveniently be fastened to loop or hook members associated with the top frame member.

There can also be provided one or two handles of an arcuate shape, enabling simple stacking of the basket, conveniently being formed from shaped wire.

To assist in manufacture, the base wires can be placed in or about a former or mould corresponding to an inside of a completed basket whereby to ensure accurate alignment for fastening.

The base lattice can be defined by mutually orthogonally arranged sets of first and second wires to provide a lattice having generally square apertures. If other angles are employed then generally diamond shaped lattice shapes can be provided. The first and second sets of parallel wires can be spaced differently from one set with respect to the other.

Conveniently the wires are fastened together by welding, either spot welding or MIG welding, as determined by the wire gauge.

Preferably, all the base wires are placed upon the former and multiple spot welds are performed in a single operation. Other fastening methods may be employed, such as by the use of solder or by the application of an adhesive.

In a final step, the basket can be provided with a suitable protective coating, conveniently of zinc plating, which plating operation is conducted after ensuring the upstanding wires are trimmed or nibbled using a nibbling machine whereby to level and round-off the wires. It will also be appreciated that any protective films of oil and production debris is removed prior to the basket being plated.

Once the basket has been plated, then handles can be fitted. As is known, when baskets are arranged to the stacked, then the shape assumed by the handles is such that they correspond with the top frame of the basket so that the handles do not interfere with the placement of any subsequent baskets once a basket has been placed within a stacking arrangement nor depend awkwardly therefrom, with a likelihood of becoming stuck with respect to another basket of the stack or handle thereof.

In accordance with a second aspect of the invention, there is provided a wire lattice basket, having been formed by at least some of the method steps described above.

In another aspect of the invention, the basket comprises a wire lattice base comprising first and second sets of straight parallel wires that are arranged substantially at right angles, one to another, the basket comprising a base comprised of wire lattice and a sidewall depending upwardly therefrom, wherein at least a portion of the sidewall is curved such that the first and second wires, wherein at the base adjoining a curved section, the wires are bent such that at a perimeter edge of the base, the wires are separated substantially equal amounts whereby to maintain a spacing between the lattice wires to a minimum.

The basket can comprise part of a trolley or be a hand-held basket.

BRIEF DESCRIPTION OF THE FIGURES

For a better understanding of the present invention, reference will now be made, by way of example only, to the Figures as shown in the accompanying drawing sheets, wherein:-Figures 1 -3 illustrate different a prior-art rectangular shopping baskets; 04 Figure 4 illustrates a perspective view of a first embodiment of the invention; o Figures 5 & 6 show first and second side views of the embodiment shown in Figure 4; 1 Figure 4a illustrates a perspective view of a second embodiment of the invention; Figures Sa & 6a show first and second side views of the second embodiment; Figures 7 & 7a show the embodiment shown in Figure 4 in plan view and a region of handle attachment, respectively; Figure 8 comprises a flow chart of the manufacturing process; and Figure 9 details a feature of an arcuate corner; and, Figure 10 shows a supermarket trolley with a basket in accordance with the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

There will now be described, by way of example only, the best mode contemplated by the inventor for carrying out the present invention. In the following description, numerous specific details are set out in order to provide a complete understanding to the present invention. It will be apparent to those skilled in the art, that the present invention may be put into practice with variations of the specific.

Referring now to Figure 4, there is shown a perspective view of a first embodiment of the invention, comprising a wire basket 40 being a generally oval in section, with two generally arcuate handles 41, 42 attached by rings mounted atop a top frame element 43. The oval basket has a first, long axis associated with a long dimension of the basket and a second, short axis, associated with a narrow dimension of the basket. Figures 5 and 6 show the wire basket as is viewed axially with respect to the long axis and the short axis, respectively. Wires extending upwardly from the base 44 meet with the top frame 43; four wire bands 45, 46, 47, 48 extend around the continuous sidewall 50 of the basket whereby to provide strength to the basket and retain the relative positions of the wires as they extend from the base. A further oval wire 49 being attached to the edge portions of the base wires.

The invention can be more completely understood with particular reference to Figure 7, where the wire basket in accordance with the invention is shown in plan view. The base wires can be seen to include certain wires from the edge that have been formed so that they are generally in correspondence with a radial axis of the oval.

Specifically, with reference to the lower right portion of Figure 7, it can be seen that, on each side parallel with the long axis of the basket a wire 71 adjacent the outermost wire 72, has an end portion 74 that is angled toward the perimeter oval wire 49. It can also be seen that, on each side parallel with the short axis of the basket the first 75 and second 76 wires adjacent the outermost wire 77, have an end portion 74 that is angled toward the perimeter oval wire 49.

It will be appreciated, dependent upon the specific dimensions of the basket, including the spacing of the wires and radius of a specific curve, that, with respect to such outer wires, there may be one, two or three wires having their base end parts 74 -that is the part of the portion of wire of the base that extends from the closed, uniform mesh formed from the two wires in separate axes toward the perimeter -being angled toward the perimeter wire so that the effective distance between wires along the perimeter of the oval are averaged out. This has the advantage, in the use of a finished basket, when, for example, a shopper in a shop places items in the basket, that small items are significantly less likely to fall through the gaps between wires at the peripheral edges of the basket.

Whilst this example is shown with respect to an oval basket in plan, the invention is equally suitable for baskets that are circular in plan and other shapes. Further, the invention shows the base wires arranged in two axes mutually perpendicular with respect to each other; the invention is also applicable to such arrangements.

Indeed, certain diamond shapes that had hitherto had not been considered could be employed to provide baskets with different, more striking characteristics.

Figures 4a, Sa and 6a, show a further embodiment. Rather than having rings welded or brazed upon the top perimeter wire 43 as shown in with reference to the first embodiment, the handles can be secured to loops 65, 66, which loops are formed from the top perimeter wire 43. This has proven to be simpler to manufacture and removes a welding/brazing stage. Indeed, it has been found that stacking is more simply enabled, since the loops can be reliably formed such that they diverge outwardly from the vertical. It also provides a greater degree of inherent strength.

With reference to Figure 8, the manufacture of a basket in accordance with the invention shall be discussed. In a first step (1) elongate rectilinear wires that are arranged along first and second parallel axes are placed in two layers, each layer comprising wires arranged along a particular axis. Conveniently the wires are placed in a former or mould corresponding to an inside of a completed basket. If such a former is used and a peripheral oval wire is internal to the basket, then such a peripheral wire would be placed prior to placement of the separate overlapping wires comprising the basket weave -although it is to be stressed that, unlike baskets made from wicker, willow etc, the wires are not actually woven one is with respect to another, rather the wires are placed one atop the other and fastened together, conveniently by welding. Although other fastening methods could be used such as by soldering or even by the use of adhesives, these methods would not be performed because of economic considerations. In the event that the wires have not been placed upon a former, then they are so placed and, next, wires that have been formed so that they are not uniformly straight and are bent so that they extend directly toward the perimeter of the base are placed upon the former and welded to wires extending from the uniform mesh section. If the base oval wire is designed so that it is external to the basket, then it would be so placed and welded. In a still further alternative, all the base wires are placed upon the former and multiple spot welds are performed in a single operation. This has the advantage of reducing the process steps and in that the base welds are performed uniformly so that, upon cooling differential contraction forces that occur upon cooling arising from the spot welds are balanced, assisting in the provision of a finished product that is not liable to distort.

In a next step, the ends of the wires extending form the oval of the base are bent upwardly and fastened to a top frame member 43.

The top frame may incorporate one or two loops or hook-like members either side of the longitudinal axis, for attachment of one or two handle member. The upstanding wires (with respect to the base section of the basket -the manufacturing automation and drives processes can be such that a basket is handled in an up-side-down orientation through one or several process stages).

Subsequently, the four wire bands 45, 46, 47, 48 are placed around the basket and welded thereto, conveniently in a single multiple spot-weld operation. In the event that hoops, hooks or the like have is not already been manufactured or placed upon the top frame, then such hoops or hooks -conveniently formed from steel rings or pressed steel washer-like elements -can be placed upon the top frame or otherwise connected to one or several upstanding wires form the base, conveniently of a suitable gauge, which may differ from the gauge of the adjacent upstanding wires. The basket is then provided with a suitable protective coating, conveniently of zinc plating, which plating operation is conducted after ensuring the upstanding wires are trimmed or nibbled using a nibbling machine whereby to level and round-off the wires. It will also be appreciated that any protective films of oil and production debris is removed prior to the basket being plated.

Once the basket has been plated, then handles can be fitted. As is known, when baskets are arranged to the stacked, then the shape assumed by the handles is such that they correspond with the top frame of the basket so that the handles do not interfere with the placement of any subsequent baskets once a basket has been placed within a stacking arrangement nor depend awkwardly therefrom, with a likelihood of becoming stuck with respect to another basket of the stack or handle thereof. Accordingly, another advantage of the present invention, for a uniform oval design of basket, can be realised in that the or each handle is of an arcuate shape.

With respect to the manufacturing process described above, for a standard shopping basket, the following gauges of wire have been used: top frame wire gauge: 5mm $; Lower oval wire gauge: 4mm $; first -fourth rim wire gauge: 3mm; minor basket line and cross wire gauge: 2mm $. Whilst the handles can be formed from many materials, it has been found that a simple galvanised steel wire having a gauge of 4.75 mm is sufficient, with a plastics sleeve being provided for comfort and grip. The some or all of the wires can be oval in section; for example, the rim wires could be replaced by oval section wires. The wires are conveniently formed from mild steel.

A basket -for shopping purposes -will be of a standard size, such as having a fifteen or nineteen litre volume. Such sizes provide a suitable volume for typical grocery shops; it will be appreciated that bespoke boutiques may require smaller baskets, with regard to the size of typical purchase. Large baskets can be created, but for consumer retail purposes, shopping trolleys will typically be provided. Notwithstanding this, despite the embodiment shown above and the manufacturing process described, the present invention can be simply extended to other designs of basket, where a non-rectangular design is required.

Figure 9 shows a detail of a corner section. Figure 10 shows a basket of the invention as part of a supermarket trolley. It will be realised that further derivatives of the invention can be simply realised. For example bespoke shapes can be created particular to a chain of supermarkets or for a particular shop, where the shape is arcuate, corresponding to, for example a logo, or a generalised shape of good that could be purchased at a particular store -by the use of wires that are formed so as to average a size of gap about an arcuate portion, between and standard mesh of the base and side-wall. The basket having a single arcuate section may comprise a stylish supermarket trolley. The lattice can comprise squares, rectangles and diamond shapes.

Claims

CLAIMS: 1. A method of making a wire lattice basket, the basket comprising a base and sidewall, the base having one or more arcuate perimeter sections extending over a plurality of lattice sections and a sidewall depending upwardly from the base perimeter, said base lattice being defined by first and second sets of parallel wires being arranged in layers one with respect to the other, the first and second sets of wires being angularly disposed in the range of 60° -900, the wires from the base extending upwardly from the sidewall to a top rim, with a number of wires being arranged about the sides of the basket; the method comprising at least the following steps: arranging straight elongate rectilinear wires in a parallel fashion along first and second axes, said first and second axes being arranged to provide a lattice base for the basket; arranging along an arcuate perimeter edge section a wire that has been bent between the lattice and the perimeter of the base, whereby to have a distal end of the wire at the perimeter spaced substantially equidistant with respect to distal ends of the wires adjacent wires at the perimeter; fastening the lattice wires together; bending the wires extending from the base about 75 -90° direction whereby to define a general basket shape; fastening a top rim to the upstanding wires; and fastening one or more rim wires about the sides of the basket.
2. A method according to claim 1, further including the step of attaching a base rim wire on or about the base, whereby to increase the structural integrity of the base.
3. A method according to claim 2, wherein the base rim wire is attached internally to the basket.
4. A method according to any one of claims 1 -3, wherein two or more loop elements are formed in the top rim prior to fastening the top rim to the upstanding wires whereby to enable a handle to be secured to said loop elements.
5. A method according to any one of claims 1 -3, further including the step of attaching hook or hoop members to the basket about the top frame whereby to enable a handle to be secured to said hook or hoop members.
6. A method according to claim 4 or 5, wherein the handle(s) is/are formed from a shaped wire.
7. A method according to any one of claims 1 -6, further including the step of placing the base wires in or about a former or mould corresponding to an inside of a completed basket.
8. A method according to any one of claims 1 -7, wherein the lattice is defined by mutually orthogonally arranged sets of first and second wires to provide a lattice having generally square apertures.
9. A method according to claim 8, wherein the first and second sets of parallel wires are spaced differently from one set with respect to the other.
10. A method according to any one of claims 1 -9, wherein the wires are fastened together by welding.
11. A method according to any one of claims 1 -9, wherein the wires are fastened together by soldering.
12. A method according to any one of claims 1 -9, wherein the wires are fastened together by the application of an adhesive.
13. A wire lattice basket, being the product of any method claim 1-12.
14. A wire lattice basket, wherein the wire lattice comprises first and second sets of straight parallel wires that are arranged substantially at right angles, one to another, the basket comprising a base comprised of wire lattice and a sidewall depending upwardly therefrom, wherein at least a portion of the sidewall is curved such that the first and second wires, wherein at the base adjoining a curved section, the wires are bent such that at a perimeter edge of the base, the wires are separated substantially equal amounts whereby to maintain a spacing between the lattice wires to a minimum.
15. A wire lattice basket, according to claim 13 or 14, wherein the basket is a hand-held basket.
16. A wire lattice basket, according to claim 13 or 14, wherein the basket comprises part of a trolley basket.