REUSABLE MODULAR CONTAINMENT DEVICE FOR PROTECTING CARGO DURING SHIPMENT
20170113863 ยท 2017-04-27
Inventors
Cpc classification
B65D2519/00666
PERFORMING OPERATIONS; TRANSPORTING
B65D2519/00333
PERFORMING OPERATIONS; TRANSPORTING
B65D2519/00039
PERFORMING OPERATIONS; TRANSPORTING
B65D19/06
PERFORMING OPERATIONS; TRANSPORTING
B65D2519/00805
PERFORMING OPERATIONS; TRANSPORTING
Y02W30/80
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B65D2519/00701
PERFORMING OPERATIONS; TRANSPORTING
B65D19/385
PERFORMING OPERATIONS; TRANSPORTING
B65D2519/00502
PERFORMING OPERATIONS; TRANSPORTING
B65D2519/00995
PERFORMING OPERATIONS; TRANSPORTING
B65D19/10
PERFORMING OPERATIONS; TRANSPORTING
B65D2519/00273
PERFORMING OPERATIONS; TRANSPORTING
B65D2519/00074
PERFORMING OPERATIONS; TRANSPORTING
B65D81/107
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65D81/107
PERFORMING OPERATIONS; TRANSPORTING
B65D19/18
PERFORMING OPERATIONS; TRANSPORTING
B65D19/08
PERFORMING OPERATIONS; TRANSPORTING
B65D19/20
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A robust, reusable, and modular shipping container for protecting large, fragile, odd-shaped, or high-value cargo from damage during shipment. Such cargo may include telecommunications cabinets, appliances, and furniture. The shipping container minimizes the possibility of shipping damage due to improper handling, tip-overs, lateral collisions, or vibration. Such a shipping container may include a pallet base, a lower frame section, an upper frame section, and a top cover, the assembly of the pallet base, lower frame section, upper frame section, and top cover defining a protective outer cage having an interior in which the cargo is disposed.
Claims
1. A sturdy, reusable, modular, shipping container for protecting large, fragile, odd-shaped, or high-value cargo from damage during shipment, comprising: a pallet base wherein the pallet base includes a rectangular frame with a plurality of vertical support members extending from a bottom side, the plurality of vertical supports spaced to form a plurality of pockets beneath the rectangular frame of the pallet base; a base pad compartment bounded by the rectangular frame of the pallet base and a base pad compartment floor, the base pad compartment configured to receive a base pad; a lower frame section with a plurality of vertical support members extending from a top of the rectangular frame of the pallet base, wherein a plurality of cross braces extend between the plurality of vertical support members; a ramp extending from a front of the pallet base wherein the ramp is movable between a first storage position within the storage container and second position exterior of the storage container, an upper frame section removably coupled to a top of the plurality of vertical support members of the lower frame section, the upper frame section including a front side and a back side, and a strike plate extending along an entire length of the front side, which retains the ramp in the first position; and a top cover; the pallet base, lower frame section, upper frame section, and top cover defining a protective outer cage having an interior in which the cargo is disposed; wherein the front side and back side of the upper frame section includes horizontal upper members and horizontal lower members and vertical side members; and wherein the lower horizontal member of the upper frame section that is the strike plate for the ramp is wider than the horizontal upper members of the upper frame section.
2. The shipping container of claim 1, wherein the base pad compartment floor includes recessed cavities into which foam, or other vibration and shock dampening material, are placed.
3. The shipping container of claim 1, wherein the ramp is connected to the pallet base by one or more hinges, such that it can be lowered to the second position for loading and unloading cargo, and stowed in the first position for shipment.
4. The shipping container of claim 1, wherein the lower frame section comprises at least first and second side members connected to the pallet base.
5. The shipping container of claim 4, wherein the sides are modular sides attached to the pallet base using one or more mating connectors.
6. The shipping container of claim 4, wherein the first and second sides include at least one frame member disposed in either a horizontal, vertical or diagonal orientation.
7. The shipping container of claim 1, wherein the upper frame section is removably coupled to the top of the plurality of vertical support members of the lower frame section by one or more mating connectors, and where the top cover is attached to the upper frame section by one or more second mating connectors.
8. The shipping container of claim 1, wherein the plurality of vertical supports have one or more third mating connectors to couple with one or more mating connectors of the pallet base.
9. The shipping container of claim 1, wherein the upper frame section comprises first, second, and third sides.
10. The shipping container of claim 1, wherein the front side and back side each include at least one bracing member of a horizontal, vertical or diagonal orientation.
11. The shipping container of claim 1, wherein the lower horizontal member of the front side is the strike plate for the ramp.
12. The shipping container of claim 1, wherein the top cover is attached to the upper frame section using mating connectors.
13. The shipping container of claim 1, wherein the top cover comprises at least one or more bracing members.
14. The shipping container of claim 13, wherein the top cover comprises a flat plate extending between a pair of opposed side members.
15. The shipping container of claim 1, wherein the pallet base and top cover each have one or more points of attachment for securing straps.
16. The shipping container of claim 1, wherein each of the front side and back side of the upper frame section includes a plurality of vertical side members, a horizontal upper member, a horizontal lower member, and a plurality of horizontal bracing members disposed between the horizontal upper member and the horizontal lower member.
17. The shipping container of claim 6, wherein each of the first and second sides includes a plurality of vertical support members, and a lower frame upper cross brace, a lower frame upper base member, and a plurality of mid cross braces extending horizontally between each of the plurality of vertical support members.
18. The shipping container of claim 1, wherein a vertical side member in the upper frame section is removably coupled to a horizontal upper member and a horizontal lower member in the upper frame section.
19. The shipping container of claim 18, wherein each of the horizontal upper member and the horizontal lower member in the upper frame section has a through hole disposed thereon; wherein the vertical side member comprises a shaft; and wherein the shaft of the vertical side member s disposed through the through holes of each of the horizontal upper member and the horizontal lower member in one of a clearance or transition fit.
20. The shipping container of claim 18, wherein each of the horizontal upper member and the horizontal lower member is connected to the vertical side member by at least one of a cam lock connector or a screw.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0052] The following drawings and description thereof are meant to exemplify one or more specific embodiments of the invention, and are not intended to limit the scope of the invention in any way.
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DETAILED DESCRIPTION
[0071] The modular, reusable, shipping container of the present invention is shown in the figures as comprising: a pallet base 100, a lower frame section 300, an upper frame section 400, and a top cover 500.
[0072] The pallet base is constructed of one or more structural materials such as steel, aluminum, wood, plastic or a composite. For many applications, steel provides a good combination of strength, weight, and low cost. The pallet base includes a floor allowing for the use of hand trucks, or appliance-type dollies, to load and unload the cargo while protecting the bottom of the cargo. The floor can include recessed cavities into which foam, or other vibration and shock dampening materials, can be placed. These materials insulate the cargo from the pallet base and absorb any vibrations or shock induced into the shipping container.
[0073] The cargo typically rests on vibration and shock-dampening material. The material supports the cargo above the floor and leaves a small space, approximately to 1, between the bottom of the cargo and the floor. This gap provides room for the cargo to float on the vibration and shock dampening material. An additional benefit of the gap is that it allows a standard appliance dolly to be slipped into it to facilitate removal of the cargo from the shipping container once the cargo has reached its final destination.
[0074] The shipping container of the present invention can further comprise a ramp, e.g., a folding ramp that can be moved between a substantially horizontal down position (for unloading cargo with an appliance dolly or hand truck), and a substantially vertical folded (i.e., stowed) position for transit. The folding ramp can be attached to the pallet base using hinges, and constructed of a suitable material (e.g., steel, aluminum, composite material, wood, or plastic) to provide a desirable combination of strength, weight, and cost for a particular application. Reinforced steel provides sufficient strength, acceptable weight, and low cost for many applications.
[0075] When the folding ramp is in the vertical stowed position, it can be secured with safety retainer mechanisms, such as safety cables or safety chains. An additional benefit of this folding ramp is that when in the stowed position, it provides additional protection against damage from forklifts or other material-handling devices by acting as a protective wall on the front side of the shipping container. Other embodiments of the present invention include a ramp which slides in and out of the pallet base, and a ramp which can be completely detached from the pallet base. When the ramp is in the open position, the ramp allows a user of the shipping container to load material onto the shipping container base with a commonly used hand truck, or appliance style dolly. When the ramp is in the stowed, or folded position, it provides additional protection to the cargo contained within the shipping container.
[0076] A lower frame section, comprising left and right sides, and optionally a back side, connects to the pallet base and extends generally upward. These sides provide skeletal-like protection for the lower portion of the shipping container, a means for supporting the upper frame sides, and a means for supporting, and hearing the weight of stacked pallets when the shipping container is used in the half-height position. Incorporated into the tops of the lower frame sides are mating connectors, which allow the upper frame sides to be attached to the lower frame sides. The frame sections are preferably made from a plurality of rectangular steel tubes dispersed in a parallel array.
[0077] The upper frame sides can be attached to the lower frame sides by engaging female mating connector of the upper frame sides with male connectors of the lower frame sides (or vice-versa), The upper frame sides can be identical, and include strike plates to further protect the cargo from accidental damage. The strike plates provide additional retention of the ramp to prevent it from unfolding and from forklifts inadvertently poking into the cargo, The strike plates can be at the same approximate height that a second level of pallets in a standard two-pallet stack for shipping would be. The upper portions of the upper frame sides can comprise mating connectors that allow the top frame side to be attached thereto with compatible mating connectors (e.g., male/female connectors).
[0078] A protective blanket can optionally be placed between the cargo and the inner surfaces of shipping container for additional protection. The protective blanket can comprise a plurality of padded features. Space filling material, such as foam pads, packing air bags, or other typical dunnage materials and items can also be inserted between the protective blanket wrapped cargo and the inner surfaces of the shipping container. For example, air bags can be placed between the cargo and the inner surfaces of the container at various locations to further eliminate any gaps between the container and the cargo. Packing air bags are available in an almost unlimited variety of sizes, shapes, and strengths from a variety of sources such as alibaba.com, Inflatable Packaging, Inc., and others.
[0079] A strap mechanism can be used to tighten the unit together. For example, a plurality of ratcheting, nylon straps can be used to bind the unit. The ratchet portion of each of the ratcheting straps can be fixed to the pallet base, and the hook end of the ratcheting strap attached to the top frame side. Once the plurality of straps has been fully tightened, the outer portion of the shipping container frame can be wrapped with a layer of stretch wrap, or with products such as shrinkwrap. The stretch wrap provides protection against external moisture, provides a surface upon which shipping labels, and tags, can be affixed to the shipping container, and a visual reference to aid in the detection of cargo damage inflicted during the shipping process.
[0080] In certain applications, the upper frame sides can be removed and the shipping container used as in half-height configuration. The upper frame sides can be stored within the lower frame sides, and the top frame side attached to the upper portions of the lower frame sides. In this configuration, the top frame side becomes the top of a half-height shipping container.
[0081] An additional benefit of the modular design of the shipping container is that it can protect a telecommunications cabinet during the assembly process. The shipping container, containing the unpopulated telecommunications cabinet, is simply moved to the first stage of the populating process. If multiple stages of assembly are required, the cabinet can be moved on the shipping container throughout the assembly process. Once assembly is complete, a protective blanket can be placed over the cabinet and the ramp secured in the stowed position with safety retainer devices. The upper frame sides can be attached; and ratcheting straps tightened. After the shipping container is wrapped with a layer of stretch wrap film, the unit is ready for shipment.
Specific Embodiment of Invention
[0082] One specific embodiment of the shipping container of the present invention is illustrated in
[0083] Turning now to
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[0085] A plurality of lower frame vertical support members 302 extend upwardly from the base of the pallet frame member 112 forming an outer perimeter for the lower transport device base assembly 100. in a preferred embodiment of the present invention, lower frame vertical support members 302 extend upwardly from each of the corners of the transport device base 100. The four vertical support members 302 of the preferred embodiment form a front right lower vertical support member 303, a rear right lower vertical support member 304, a left rear vertical support member 306, and a left front vertical support member 305.
[0086] A plurality of cross braces fixedly connecting the right front lower support member 303 and the right rear lower support member 304. In a preferred embodiment of the present invention the cross braces include a right to frame upper base member 320, a right lower frame mid cross brace 322, and a right lower frame upper cross brace 323. Each of the cross braces 320, 322, 323 are fixedly attached in a perpendicular orientation to the right rear vertical support member 304 and the right front lower vertical support member 303.
[0087] Fixedly connecting the left front lower vertical support member 305 and the left rear lower vertical support member 306 are a plurality of cross braces and in a preferred embodiment of the present invention comprise a left lower frame upper base member 310, a left lower frame mid cross brace 312, and a left lower frame upper cross brace 313. Each of the cross braces are fixedly attached in a perpendicular orientation to the left rear vertical support member 305 and the right front lower vertical support member 303.
[0088] Fixedly connecting the left rear lower vertical support member 306 to the right rear vertical support member 304 are a plurality of cross braces. The rear lower frame 320 is fixedly connected to the lower portion of the left rear lower vertical support member 306 at a first end 342, and fixedly connected to the lower portion of the right rear 304 vertical support member at a second end 344. In a preferred embodiment, a second rear lower frame mid brace 340 is also fixedly connected to both the left rear lower vertical support member 306 at a first end 342, and fixedly connected to the lower portion of the right rear vertical support member at a second end 344.
[0089] Fixedly connecting the left front lower vertical support member 305 to the right front vertical support member 303 is a front lower frame 350. The front lower frame 350 has a first end 352 and a second end 354. The first end 352 of the front lower frame member 350 is fixedly attached to the lower portion of the lower portion of the right front vertical support member 303 in a perpendicular orientation. The second end 354 is fixedly connected to the lower portion of the left front vertical support member 305.
[0090] Fixedly attached to the top portion of the front lower frame member 350 and extending to the top portion of the rear lower frame member 330 is the base floor 120. Fixedly attached to the bottom portion of the front lower frame member 350 and extending to the lower portion of the rear lower frame member is the pad compartment floor 132.
[0091] The base floor comprises a right side 121, a left side 122, a front side 123, a back side 124, a top side 125, and a bottom side (not shown). The top side 125 of the floor 120 faces in a generally upward direction and provides a surface capable of supporting a hand truck) or dolly, when such device is used for the loading and unloading of cargo from the transport device.
[0092] The right side 121 and left side 122 of the base floor 120 form part of the outer perimeter of each of the base pad compartments 130.
[0093] The base pad compartment 130 is bounded by the front lower frame member 350, the rear lower frame member 330, the left lower frame upper base member 310, the right lower frame upper cross brace 323, and a base pad compartment floor 132.
[0094] The base pad compartment 130 is capable of holding a base pad 140. Turning now to
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[0096] Additional ramp retention is provided by ramp safety retainers 240. The ramp safety retainers 240 prevent the ramp member 210 of the ramp assembly 200 from accidently unfolding when the front upper frame member 410 is removed from the lower frame 300.
[0097] In a preferred embodiment of the present invention, the upper frame strike plate 412 and rear upper frame strike plate 422 are wider than other frame members such as the upper mid braces 414 and 424 in order to provide additional protection to the cargo 800 from potential damage to fork strikes and other material handling equipment issues.
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[0099] Additional components of the ramp assembly 200 can be seen in
[0100] The ramp member 210 further comprises an upper facing 212 and a lower facing 214 portion. The upper facing 212 may further comprise a non-skid surface, or other suitable surface to increase the suitability of the ramp member 212 for use. In a preferred embodiment of the present invention, the ramp member 210 and floor member of the transport device base 120 are constructed of diamond plated aluminum. The bottom side of the ramp member 210 may further comprise a plurality of support members 220 which provide additional support to the ramp member 210.
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[0108] The lower portion of the upper frame member 300 frame uprights 418, 419, 420, and 422 further comprise a female mating receptacle 450 capable of receiving the male upper male attachment posts 390 of the lower frame assembly 300.
[0109] Exemplary
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[0111] In a preferred embodiment of the present invention, the front upper frame 410 and rear upper frame 420 are interchangeable.
[0112] Turning now to
[0113] Fixedly connected to the left top frame member 504 and right top frame member 506 are a plurality of top frame strap connection members 522. Turning back to
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[0117] In an exemplary embodiment, an upper frame member may have an upper horizontal support member 416 and a lower horizontal support member 412, as well as a plurality of horizontal bracing members 414 which may connect side members 418 and 419. Connections between members may be permanent or may be coupled using mating features. For example, according to an exemplary embodiment, horizontal bracing members 414, or other members, may be removably coupled to the side members 418 by one or more connectors 440, which may be, for example, screws, cam lock connectors, or another such connector, as desired.
[0118] Turning now to exemplary
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[0121] In an exemplary embodiment, a top cover 500 may include a plurality of side-mounted top frame strap connection members 522. In an exemplary embodiment, one or more straps may be connected from a side-mounted top frame strap connection member 522 to another structural element, such as an upper or lower frame. According to an exemplary embodiment, a top frame strap connection member 522 may be mounted on the side in order to permit ease of access to a strap. In an exemplary embodiment, a top cover 500 may further include a downward-facing portion, which may function as a receiver member 520. Receiver member 520 may interlock with the geometry of the top portion of the upper frame section, such as with mating features 460 of the upper frame section, and may ensure that the top cover 500 does not shift on top of the upper frame section.
[0122] Turning now to exemplary
[0123] Turning now to exemplary
[0124] According to an exemplary embodiment, the base pallet assembly portion 110 may be incorporated into the lower frame section 300 such that the vertical support members 302 extend from the top portion of the lower frame section 300 to the bottom portion of the base pallet assembly portion 110. In an exemplary embodiment, a base floor 120 may be disposed slightly above the lower portion of the vertical support members 302.