Abstract
The present invention relates to the field of the transportation and storage of goods, to a modular container for shipping and handling cargo and to a storage system therefor, and to such a container that may be easily assembled or disassembled. In particular, but not necessarily restricted thereto, the present invention relates to a system for the transportation and storage of palletized goods.
Claims
1. A transport/storage enclosure for enclosing a product with respect to a support surface, the enclosure comprising a four sided form arranged as a general rectangular body, with five external panels, having a length and a width; the enclosure comprising at least first and second rectangular sheet products, each comprising first and second fold lines whereby to produce a panel having three rectangular wall sections, respectively first, second, and third rectangular sections, wherein the first and second sheet materials, upon assembly are arranged such that they comprise two sheet elements having a cross-section of a general “C”-shape, with the first and third arms of the sheet products defining an opening, which respective openings face each other to define a rectangular enclosure; the enclosure further comprising a third rectangular sheet product, comprising first and second fold lines whereby to produce a panel having three rectangular wall sections, respectively first, second, and third rectangular sections, wherein the third sheet materials, upon assembly is arranged such that it comprises a sheet element having a cross-section of a general “C”-shape, the length of the central section being less than the corresponding section of the first and second sheet products, with the length of the first and third panels being less than the corresponding section of the first and second sheet products, whereby the third sheet product divides the enclosure, with the first and third wall sections being placed parallel to the corresponding wall sections of the first and second rectangular sheet products; the enclosure further comprising a lid which closes rectangular arrangement, the lid having a downwardly depending lip about its perimeter and channels operable to engage with the upstanding edges of the sheet product elements, to define an upright rectangular quadrangle arrangement operable to surround two or more pallets and any load carried thereon, the lid being of a two part construction, with the two parts being separable along a partition along the length.
2. A transport/storage enclosure according to claim 1, wherein a single third rectangular wall section is provided wherein the central section of the third rectangular wall section is operably arranged adjacent first and third, coplanar sheets, with the first and third panels act as divider partitions between, respectively first and second and second and third enclosures for palletized goods, the uppermost portions of the sheets engaging within the lid member.
3. A transport/storage enclosure according to claim 1, wherein a single third rectangular wall section is provided wherein the central section of the third rectangular wall section is operably arranged adjacent first and third, coplanar sheets of the exterior walls of the enclosure, and folded back whereby to permit the first and third sheet panels of the third rectangular wall portion to extend perpendicularly, whereby to jointly act as a divider partition between first and second enclosures for palletized goods, the uppermost portions of the sheets engaging within the lid member.
4. A transport/storage enclosure according to claim 2 or 3, wherein a further panel depends from at least one of the first and third panels of the third rectangular sheet portion, whereby to fully enclose at least one of the divided interior sections.
5. A transport/storage enclosure according to claim 1, wherein there are two third rectangular wall sections, each arranged such that there is provided a central section, with two depending sections each other side of the central wall section, whereby to provide a general “C”-shape in plan, wherein the central sections are operably arranged facing each other such that in a first mode of operation there are arranged such that the C-sections face each other whereby to divide the enclosure into three distinct interior sections and in a second mode of operation are arranged in such that the “C”-sections are facing way from each other whereby to divide the enclosure into two distinct interior sections.
6. A transport/storage enclosure according to any one of claims 1-5, wherein the sheet panels/wall sections are formed from one of corrugated cardboard, corrugated plastics, extruded plastics and multi-layered plastics.
7. A transport/storage enclosure according to any one of claims 1-6, wherein the lid is provided with slide bolts operable to engage with apertures placed proximate to the upstanding edges of the sheet product elements.
8. A transport/storage enclosure according to claim 7, wherein the slide bolts are provided with engagement means operable to secure tamper evident ties.
9. A transport/storage enclosure according to claim 7, wherein the slide bolts are provided with locking means operable to secure the lid to the sheet product elements.
10. A transport/storage enclosure according to any one of claims 1-9, wherein the lid is comprised of two portions, whereby removal of one lid element permits the enclosure to remain secure yet permit the walls of one side of the enclosure to be hingedly opened, to enable access to the enclosure.
11. A transport/storage enclosure according to any one of claims 1-9, wherein the sheet materials employed for the fabrication of the rectangular sheet can be selected from the corrugated cardboard and/or corrugated plastics.
12. A transport/storage enclosure according to any one of claims 1-11, wherein the lids are provided with handles that can be stowed flat.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0022] 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:-
[0023] FIGS. 1a-1b illustrate two known forms of pallet;
[0024] FIGS. 2a and 2b illustrate an arrangement of pallets upon racks and within a commercial vehicle;
[0025] FIGS. 2c.i-2c.iiii show how pallets are typically loaded;
[0026] FIGS. 3a-c show prior art pallet systems;
[0027] FIG. 4 shows a loaded pallet;
[0028] FIGS. 5a & 5b show a first embodiment of the invention in side and front perspective views, respectively;
[0029] FIGS. 5c & 5d show the first embodiment of the invention in side and front perspective views, respectively with a secondary load placed upon the enclosure;
[0030] FIGS. 6a-6b show the two separate corrugated board types of component that are utilised in the manufacture of an enclosure in accordance with the invention;
[0031] FIG. 6c shows an upper main face of a first enclosure lid made in accordance with the invention;
[0032] FIGS. 6d-6i detail a second enclosure lid and
[0033] FIGS. 7a-7n show the steps of assembly and loading an enclosure in accordance with two embodiments in accordance with the present invention;
[0034] FIG. 8a shows a variation in the division of the internal volume;
[0035] FIG. 8b-8d show an enclosure with two divisions in various states of closure;
[0036] FIG. 8e details how the lid and wall components of the present invention can be securely fastened together;
[0037] FIG. 9a-9a″ show a top plan view, a side view and an underside plan view of a lid arrangement;
[0038] FIGS. 9b and 9c show how the internal walls can be placed to divide the internal volume of an enclosure in accordance with the present invention;
[0039] FIG. 10a shows a stack of lids;
[0040] FIGS. 10b & 10c show how six lid-pallet kits can be stacked, two types of pallet respectively of wood and moulded plastics; and,
[0041] FIGS. 11a to 11f show first and side views of a system in accordance with the invention in use, with plan and perspective views thereof with different types of pallet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] 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.
[0043] FIG. 4 shows an example of a pallet 20 supporting a load 42; the load placed upon the pallet so that the outer extent of the load corresponds with the area of the pallet base. Whilst the pallet 20 is not shown in any great detail, it is manufactured from wood and is a four-way entry pallet, wherein the tines of a fork lift or similar tined lifting device can insert its tines through gaps typically having a lower-most height of 100-120 mm, but this will vary, dependent upon the material of manufacture of the pallet and the load to be supported.
[0044] FIG. 5a shows a first embodiment of the invention 51, in a state of completion showing first and second exterior panels 52, 53—each comprising an elongate rectangular sheet of corrugated board, with the corrugations of the board extending transversely to the longer dimension of the rectangular board. Two transverse creases 56, 57, parallel with the corrugations enable the panel to be folded into three sections, 53′, 53″ & 53″; upon erection, a long edge of the panel is placed upon the support surface—which could be a warehouse floor, the flatbed of a lorry or another enclosure in accordance with the invention—such that sections 53′, 53″ & 53′″ are arranged in a general “C” fashion shape to define a rectangular cuboid enclosure constructed from three sheet material components 56, 57 & 59. The lid elements 54 are provided with locking systems 58 which enable them to locate with apertures present in the panels 52, 53, as shall be discussed in greater detail below. In FIG. 5b, there is a gap between adjacent panels 52 and 53; goods 59 are effectively enclosed. It will be appreciated that the goods may well have packaging present to obscure the type of good retained with the enclosure; equally dependent leaves could be provided whereby to ensure that the nature of the packaging or the goods 59 are not visible. FIGS. 5c and 5d show how the enclosures 51, as seen from side perspective and front perspective views can support a load 59′ upon a pallet 20.
[0045] Referring now to the upright sheets of rectangular corrugated board as shown in FIGS. 6a and 6b—noting that FIG. 6a shows a panel corresponding to the external panels 52, 53 as shown above: in addition there is a further rectangular panel 61, also comprising an elongate rectangular sheet of corrugated board, with the corrugations of the board extending transversely to the longer dimension of the rectangular board. Two transverse creases 65, 67, parallel with the corrugations enable the panel to be folded into three sections, 61′, 61″ & 61′″. This member is used as an internal division and structural support member, which can also assist in identification, by having a container enclosure identification and compartment identification. With reference to FIGS. 6c and 6d, a lid 54 is shown—noting that two lids are employed in the embodiment shown in FIGS. 5a and 5b—which has slide control elements 64 on an upper surface of the lid.
[0046] FIG. 6d shows a second type of lid 54 in accordance with a variant of the invention: with this model, there is only one slide locking element 64 on the short side of the lid. FIG. 6e details the slide lock 64 having a slide bolt element 64ii retained by housing 64i. FIG. 6f details in plan view a hand hold band 66 conveniently formed from an elastomeric plastics material, but could be formed from canvas or other similar fabrics/materials. FIG. 6g shows a side view of the lid 54. FIGS. 6h and 6i show an underside view of the lid 54 and a section on line h—h, respectively. A peripheral channel 67 is shown on an inside surface of the lid 54, which are arranged to accept the upstanding edges of wall elements 52 & 53. Reference numeral 68 indicates a further channel to enable the upstanding portions 69 of panel 61″ to engage with an inside face of the lid 54, of the internal support and divider panel, for example. The inside of the channel can be provided with resilient means and/or the protrusions to engage with corrugate panels, to reduce any flexing that may occur when the enclosure is placed upon a relatively flexible flatbed of a vehicle, for example. It will be noted that a slide bolt mechanism (or similar functional equivalent) is arranged so as to engage with the apertures 62 just under the top edge of the upstanding wall members 52, 54, & 61. There are also placed “U”-shaped indentations 63 along the middle top edge of the upstanding elements 52, 61, which are situated to permit, for example, a depending corner edge of the lid to pass around the edge panel 52″; equally the “U”-shaped indentation 61 along the upper edge of panel 51″ permit a mid length depending part of the lid to pass within such “U”-shaped groove. Nevertheless, it has not proven to be essential that a lock in the central channel 67 is provided, but such a locking system could be provided if necessary, for example through customer choice. FIG. 6i also indicates the handle 66 provided to assist in handling of the lid components. Whilst the total weight of the panel is not great—in the region of 2-10 Kg—being dependent upon the anticipated loads, a width of approximately 2.5 m and a depth of some two thirds of a meter, the spaced apart handles can assist in enabling the lid to be easily manageable as a product that will be handled by personnel in use.
[0047] FIG. 7a show how the two main external upstanding corrugated sheet material members 52, 53. With respective far panels 52′, 53′ arranged in a coplanar fashion, each being perpendicular to corresponding mid panels 52″, 53″ about respective hinge creases 57. FIG. 7b differs in that two upstanding inside division and support corrugate sections 61 are employed to enable three compartments to be defined, noting that the first elements 61′ are placed in a coplanar fashion against the inside faces of corresponding external wall sections 52′ and 53′ such that the apertures 62 are in correspondence, such that when the lid element 54 is placed over—per FIGS. 7c & 7d, the slide bolts can engage through the corresponding apertures 62. A striking plate can be provided to assist in engagement, conveniently bevelled to ensure that the bolt is urged through the aperture 62. FIG. 7c show how first and third palletized goods 59.sup.#1 and 59.sup.#3 can be place at opposite ends of the enclosure, with FIG. 7d indicating placement of 59.sup.#2, the second, or central, palletized goods. Conveniently, the housing is dimensioned such that the width is slightly in excess of 2.4 m and the depth is slightly in excess of 1.2 m. This permits three Euro pallets, with dimensions of 0.8 m and 1.2 m to be accommodated or to have two 1.2 m×1.2 m pallets side-by-side, using the same exterior shell. As mentioned elsewhere, it is preferable that tri-layer polypropylene corrugated sheet is employed. More preferably, a middle layer is provided with an open three-dimensional structure spaced section, as are known, for example as Akyboard, by DS Smith, being a 3-layer polypropylene panel. With reference to FIG. 7a1, there is show a typical board, combining a central thermoformed layer CT and two solid sheets MT & ET with in-line lamination. The central area comprises a pattern of upstanding, interconnected polygons, referred to by DS Smith as an aerated section and contributes to the panel being of high strength yet lightweight. At the end of its useful life, it can be entirely recycled into new products. Such forms of corrugated and extruded material, benefit from having an ability to be bent along one axis of corrugation/heat treatment, yet when returned to a relaxed state, do not show significant indications of having been folded over. Indeed, it is understood that the corners defined in such sheet material acting as exterior and internal wall sections, with the flutings/linear elemental pattern arranged in a vertical orientation. Conveniently, vertical pinch welds in the bubble sheet material thereby creating a flat section which permits personnel to fold the sleeve through almost 330° about the feature. The top and bottom edges of the corrugated sleeve material can also be heated/pinch welded to prevent the ingress of water/debris and also a tapered edge that fits more easily into the recessed channel within lid sections. The lid sections are conveniently formed from a thermoplastics material, where non-planar features can assist in providing rigidity without unnecessary weight. The lid elements may be arranged such that clip together; a first member may be permitted to rotate with respect to the other, for convenience. It has been found suitable to provide exterior walls having a thickness of a 11 m and a weight of 3.5 Kg/m.sup.2, with the interior divider walls conveniently being of a lighter weight, such as 6.2 mm and a weight of 1.5 Kg/m.sup.2— providing significant weight benefits, given that the weight of the panels for a 2.45×1.24 times 1.18 m enclosure can amount to less than 19 Kg, together with the weight of the thermo formed lids being 10 Kg.
[0048] Referring now to FIGS. 7f-7i, there are shown respectively, a plan view of the outer enclosure 52, an end-on view of the end (middle) panel and side panels and a perspective view. FIG. 7j shows a first alternative to a middle enclosure 61.1, comprising an end panel 61.1′, two pallet load separator panels 61.1′″ and two door elements 61′″. As seen in FIGS. 7k and 7l, the interior dividing panel permits the enclosure of a single pallet load (of three for an enclosure in accordance the invention or for two larger pallet loads, when the plan view of FIG. 7I is adopter, the thinner corrugate sheet material permitting the corrugate board 61.1′ to be folded back upon itself. The views of FIGS. 7m and 7n show the dividing panels 61.1″ and end panel 61.1′ in side view, noting that reference numeral 58 indicates an area for a hook and loop fastener and apertures 62 provide apertures for locking members bolts to pass through, whilst conveniently being providing a secure hand-hold for use in manoeuvring panels upon erection of an enclosure in accordance with the present invention.
[0049] FIG. 8a shows how the inside separation corrugated boards 61′″ in accordance with the first embodiment—can be interchanged in their relative positions such that they divide the volume into three rather than just two volumes: the “C”-plan of the board 61 is interchanged so that the “C”-plans are now directed away from each other. Whilst no palletized goods are shown, the panels 52′″, 53′″ are ready to be brought toward the inside walls 61′″ of the internal board 61, so that they are parallel with the first set of co-planar panels on the other side of the enclosure, 52′, 53′ with is directed towards the ends rather than towards themselves. FIG. 8 shows a similar arrangement save for the fact that the load elements 59.sup.#1-59.sup.#3 are arranged therein, noting that bolt latch apertures 62 on panels 61′″ are aligned with apertures 62 of external panels 52′″ and 53′″. FIG. 8c shows a front perspective view corresponding to the side perspective view of FIG. 8b; FIG. 8d shows the panels 52′″ and 53′″ parallel with the sides of the palletized goods. FIG. 8e shows in detail how the bolt elements 64 are arranged to locate with apertures 62 proximate to an upper edge surface of panel 53″.
[0050] FIG. 9a shows two panels 54 sufficient to enclose different loads FIGS. 9a′ and 9a″ show a side view and underside view of this embodiment, respectively. With reference to FIG. 9b, the overall enclosure footprint 91 dimensions of 1275 depth×2475 width enable typical 40″×48″ (1200 mm×1200 mm) pallets to be enclosed in use, whilst an arrangement of three pallets is possible if using a Euro-pallet with dimensions of 1200 mm×800 mm. It will be appreciated that the locking bolts 64 can be provided with tamper evident fasteners/tags to ensure that any opening of an enclosure in accordance with the invention is indicated whereby to confirm a possibility that the enclosure assembly has been tampered with. Equally locking bolt mechanisms could also be provided. Other features that could be implemented include the provision of hand-hold apertures within the side wall panels, to assist in placement thereof. It will be appreciated by having one cover for up to three pallets, the protection of loads can be facilitated by the present invention. Referring back to FIGS. 5d & 5c, it is shown how, upon fabrication, a second set of three pallets 59, together with load can be placed upon the base enclosure system 51.
[0051] The panels are conveniently formed from materials such as corrugated cardboard sheet and corrugated plastics sheet which are widely employed in the packaging industry. It will be appreciated that by the use of corrugated sheet materials, the sheets have a good degree of rigidity, which is of benefit in a number of areas, for example in the provision of the apertures 62 and other features defined in the side panels.
[0052] FIG. 10a shows how a stack of thirty lids 54 can be placed one atop another. It will be appreciated that the displacement of a minimal volume of return and storage purposes can be extremely beneficial and advantageous from a reduced “dead space” requirement for such return travel and storage issues. The height of the stack, together with a pallet of standard dimensions has been shown to be less than 1.9 meters. FIGS. 10b & 10c show how six kits can be stacked, with each kit comprising a lid and pallet. Dependent on the height, strength and stability of the assemblies and the ability of the operator to see clearly, taller stacks may only be built following detailed consultation with the manufacturer or other competent authority. FIGS. 11a and 11b show how an enclosure in accordance with the invention can be employed simply as a base enclosure 51 upon which a further arrangement of pallets 11 can be placed, FIG. 11b being a cross-section through FIG. 11a at H-H. The pallets employed in a system may well be pre-existing pallets. Equally, the present invention may be distributed as a complete system including the pallets, which may well be formed from a plastic material such as polypropylene, as is known. FIGS. 11c-11f show how plan views of pallets correspond, and how the same external dimension of enclosure so easily accommodate different types of pallets in differing arrangements.
[0053] In the manufacture of development products, high performance corrugated board specifically developed for heavy-duty packaging applications. There are typically several standard board grades, and widths ranging from 3 mm, to 15 mm, with differentiators including the weight of the papers and the flute profiles, as well as the number of corrugations, the use of wet strength resins and wet strength adhesives to give good-excellent performance in moist or humid conditions. It has been found to be satisfactory to employ 11 mm ( 7/16″) thick panels from polypropylene with regard to the outer panels—equating to a weight of 0.35 kgm.sup.−2 and 6.2 mm (¼″) thick, with a corresponding weight of 0.15 kgm.sup.−2. It is also possible to coat the board to provide further moisture protection, for example. The present invention can thus provide a simple to erect yet secure enclosure for a load, conveniently placed upon a pallet. Therefore the load is shielded from dust and other interference; the load cannot be tampered with easily and further loads can be placed upon the cover.
[0054] Cardboard panels can also be used in addition to plastics corrugated materials. Cardboard for use in the present invention can be reinforced to a degree suitable for purpose: conveniently, the cardboard sleeve is made from industry standard single, double, triple or quadruple corrugated cardboard. In view of the ability of untreated cardboard to absorb water from precipitation or from the atmosphere, the cardboard should be adequately treated, by wax, resin, paint or other known waterproofing methods. When using corrugated board formed from 440 gm.sup.−2 wet strength Kraft paper, this type of board has a weather resistance which satisfies a 2 hour water immersion test without any ply separation. This can benefit the recyclability of the product.
[0055] In addition to a requirement for waterproofing, in order to strengthen the material, one or more of a number of options may be selected: the number of layers of sheets may be increased—e.g. for a corrugated board, the sheets as a whole, or merely just the corner sections, can be reinforced so that they have two, three of more layers; any corrugated flutes could be filled with elongate support members or strengthening members, which could be plastic rod, metal, wood or any of a number of alternative materials which can be placed within the corrugation flutes, conveniently glued or otherwise permanently attached.
[0056] Whilst the present invention enables greater flexibility in the positioning of loads with respect to a support surface and a stacking thereof, such stacking should only be performed subject to the ability of a storage/distribution warehouse/facility floor, flat bed of a commercial vehicle or base-level transport/storage assemblies to take additional weight. It is to be noted that the enclosure in accordance with the present invention is capable of providing a rectangular surround for a product to be transported or stored and will always cooperate with a corresponding support surface.
