U.S. patent application number 10/936120 was filed with the patent office on 2006-03-09 for shipping base.
Invention is credited to James E. Johanson.
Application Number | 20060049070 10/936120 |
Document ID | / |
Family ID | 35995115 |
Filed Date | 2006-03-09 |
United States Patent
Application |
20060049070 |
Kind Code |
A1 |
Johanson; James E. |
March 9, 2006 |
Shipping base
Abstract
A base for shipping or storing an appliance or other article
comprises a frame, the frame comprising rails, at least one rail
comprising two outer upright walls, at least two intermediate walls
between the outer walls, webs joining the bottom of each outer wall
to the bottom of the adjacent intermediate wall, and at least one
web joining together the intermediate walls.
Inventors: |
Johanson; James E.; (Old
Chatham, NY) |
Correspondence
Address: |
IP GROUP OF DLA PIPER RUDNICK GRAY CARY US LLP
1650 MARKET ST
SUITE 4900
PHILADELPHIA
PA
19103
US
|
Family ID: |
35995115 |
Appl. No.: |
10/936120 |
Filed: |
September 8, 2004 |
Current U.S.
Class: |
206/320 ;
108/55.1 |
Current CPC
Class: |
B65D 19/0002 20130101;
B65D 2585/6855 20130101 |
Class at
Publication: |
206/320 ;
108/055.1 |
International
Class: |
B65D 85/00 20060101
B65D085/00; B65D 19/44 20060101 B65D019/44 |
Claims
1. A base for shipping or storing an article, the base comprising a
frame, the frame comprising rails, at least one rail comprising two
outer upright walls, with respect to a normal orientation of the
base in use, at least two intermediate walls between the outer
walls, webs joining the bottom of each outer wall to the bottom of
the adjacent intermediate wall, and at least one web joining
together the intermediate walls.
2. A base according to claim 1, wherein the outer walls are
solid.
3. A base according to claim 1, wherein at least one intermediate
wall is of truss construction.
4. A base according to claim 1, wherein the at least one rail has
exactly four walls, with the tops of the two intermediate walls
being joined by a single horizontal web.
5. A base according to claim 1, wherein the face of the base that
is upwards in the normal orientation in use is provided with
formations to engage, support, or retain an appliance or other
article on the base.
6. A base according to claim 5, wherein the upward face of the base
is provided with sockets to receive feet of an appliance.
7. A base according to claim 5, wherein the upward face of the base
is provided with supports for lower edges of a frame or bodywork of
an appliance.
8. A combination of: a base for shipping or storing an article, the
base comprising a frame, the frame comprising rails, at least one
rail comprising two outer upright walls, with respect to a normal
orientation of the base in use, at least two intermediate walls
between the outer walls, webs joining the bottom of each outer wall
to the bottom of the adjacent intermediate wall, and at least one
web joining together the intermediate walls; and an article mounted
on the base.
9. A combination according to claim 8, wherein the article mounted
on the base is a domestic appliance.
10. A shipping base comprising a frame with at least one rail
having longitudinal walls connected by webs alternately at the top
and the bottom, wherein at least two bottom webs are solid and are
joined along the length of the rail directly to solid walls.
11. A shipping base according to claim 10, wherein the solid walls
are solid from the said bottom webs over at least a major portion
of the height of the rail.
12. A shipping base according to claim 10, wherein the solid walls
are at the sides of the rail.
13. A shipping base according to claim 10, wherein each said bottom
web has two side edges and is joined directly along one side edge
to a solid wall and along the other side edge to a wall of truss
construction.
14. A shipping base according to claim 10, wherein the top face of
the base is provided with formations to engage, support, or retain
an appliance or other article on the base.
15. A shipping base according to claim 14, wherein the top face of
the base is provided with sockets to receive feet of an
appliance.
16. A shipping base according to claim 14, wherein the top face of
the base is provided with supports for lower edges of a frame or
bodywork of an appliance.
17. A shipping base according to claim 10 that is generally
rectangular and comprises two said rails forming opposite sides of
the generally rectangular shape.
18. A base comprising rails meeting at corners, wherein at least
one rail comprises: a first solid side wall; a first solid bottom
web joined to the first solid side wall along the bottom edge of
the first solid side wall and a first side of the first solid
bottom web; a first internal wall joined to the first solid bottom
web along the bottom edge of the first internal wall and a second
side of the first solid bottom web; a top web joined to the first
internal wall along the top edge of the first internal wall and a
first side of the top web; a second internal wall joined to the
first top web along the top edge of the second internal wall and a
second side of the top web; a second solid bottom web joined to the
second internal wall along the bottom edge of the second internal
wall and a first side of the second solid bottom web; and a second
solid side wall joined to the second solid bottom web along the
bottom edge of the second solid side wall and a second side of the
second solid bottom web.
19. A base according to claim 18, wherein the first internal wall
is of lattice construction.
20. A base according to claim 18, wherein the second internal wall
is of lattice construction.
21. A base according to claim 18, wherein the top web is of lattice
construction.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a shipping base for articles
including household appliances and the like.
BACKGROUND OF THE INVENTION
[0002] Household appliances, such as washing machines, dryers and
the like, need to be delivered from the factory, to the store and
to the customer in an undamaged condition. Such appliances are
typically large, bulky and/or heavy. The exterior of such
appliances commonly consists of a skin of metal panels that, for
reasons of weight and economy, are not particularly robust. Also,
such appliances often have exposed operable parts or connectors.
The positioning of these elements and/or their proximity to the
outer periphery of the appliance may place them at risk of damage
during shipment and delivery. Delivery of a damaged or inoperable
appliance can have a significant effect on customer satisfaction
with a brand or a retailer. Even superficial damage to the exterior
panels can easily render the appliance unacceptable to the customer
and ultimately saleable only at an extremely reduced price. It is
therefore desirable to provide for the support and protection of
the appliance during shipping and delivery so as to avoid
structural and cosmetic damage.
[0003] Appliances are sometimes shipped mounted on a base or
pallet, which supports the bottom end and which is often slightly
larger than the appliance itself. The base is designed to be
handled mechanically, such as by a forklift, hand truck or the
like. The base serves to protect the appliance by providing a
relatively rigid and stable support or engagement surface. When
being moved, the lifting mechanism will engage the base, typically
without engaging the appliance itself.
[0004] One example of a prior shipping base, which was proposed for
use with large appliances, is shown in published U.S. Patent
Application No. 2003/0057342, which is incorporated herein by
reference in its entirety. This shipping base comprises a
rectangular frame of molded plastic. The sides or rails of the
frame comprise upright walls. Each pair of adjacent walls is joined
by a horizontal web. The webs are alternately at the top and
bottom. The exposed walls at the sides of the rails, facing
outwards and facing into the open interior of the frame, are solid.
The other walls are of lattice construction, for light weight and
economy of material.
[0005] Terms such as "top," "bottom" and "horizontal" as used in
this specification refer to the relative position of the features
in use of the base, resting on a horizontal support with an
appliance or other article mounted on it. The "upright" walls are
then typically a few degrees off vertical, for ease of molding.
SUMMARY OF THE INVENTION
[0006] One embodiment of the invention provides a base for shipping
or storing an article, the base comprising a frame, the frame
comprising rails, at least one rail comprising two outer upright
walls, with respect to a normal orientation of the base in use, at
least two intermediate walls between the outer walls, webs joining
the bottom of each outer wall to the bottom of the adjacent
intermediate wall, and at least one web joining together the
intermediate walls.
[0007] The outer walls may be solid. Some or all of the
intermediate walls may be of trussed or other open construction.
The at least one rail may have exactly four walls, with the tops of
the two intermediate walls being joined by a single horizontal web,
so that the rail as a whole has a roughly W-shaped
cross-section.
[0008] Another embodiment of the invention provides a shipping base
comprising a frame with at least one rail having longitudinal walls
connected by webs alternately at the top and the bottom, wherein at
least two bottom webs are solid and are joined along the length of
the rail directly to solid walls.
[0009] A further embodiment of the invention provides a base
comprising rails meeting at corners. At least one rail comprises a
first solid side wall. A first solid bottom web is joined to the
first solid side wall along the bottom edge of the first solid side
wall and a first side of the first solid bottom web. A first
internal wall is joined to the first solid bottom web along the
bottom edge of the first internal wall and a second side of the
first solid bottom web. A top web is joined to the first internal
wall along the top edge of the first internal wall and a first side
of the top web. A second internal wall is joined to the first top
web along the top edge of the second internal wall and a second
side of the top web. A second solid bottom web is joined to the
second internal wall along the bottom edge of the second internal
wall and a first side of the second solid bottom web. A second
solid side wall is joined to the second solid bottom web along the
bottom edge of the second solid side wall and a second side of the
second solid bottom web.
[0010] The face of the base that is upwards in the normal
orientation in use may be provided with formations to engage,
support, and/or retain an appliance or other article on the base.
For example, the base may be provided with sockets to receive feet
of such an appliance, or with supports for lower edges of a frame
or bodywork of such an appliance. Examples of such supports are
shown in above-mentioned patent application no. 2003/0057342 in the
form of projecting ribs 100. Examples of such sockets are shown in
above-mentioned patent application no. 2003/0057342 in the form of
sockets 14 and 120.
[0011] Another embodiment of the invention provides a combination
of a base according to the invention and an appliance or other
article mounted on the base.
[0012] The basic aspects of the present invention may be combined
in a number of forms. The preferred aspects of the various
constructions may be used in conjunction with one another or used
alone. The various features provide certain advantages over the
prior art. These advantages will be described herein and will be
understood by those skilled in the art upon reviewing the
description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For the purpose of illustrating the invention, there are
shown in the drawings forms of the invention which are presently
preferred; it being understood, however, that this invention is not
limited to the precise arrangements and instrumentalities shown. In
the drawings:
[0014] FIG. 1 shows an isometric top view of one embodiment of a
shipping base according to the invention.
[0015] FIG. 2 shows an isometric bottom view of the shipping base
shown in FIG. 1.
[0016] FIG. 3 is a schematic section along the line 3-3 in FIG.
1.
[0017] FIG. 4 is a side view of a base according to the invention,
with an appliance mounted on it, supported on a conveyor
device.
DETAILED DESCRIPTION
[0018] Referring to the accompanying drawings, where like numerals
identify like elements, there is shown one form of a shipping base
according to the present invention, which is identified generally
by reference numeral 20. The shipping base 20 is preferably
injection molded from a plastic material, such as polypropylene.
The specific polymer, filler or reinforcement material can be
varied to meet the specific requirements of the application.
[0019] Throughout this specification, terms such as "top",
"bottom," and "vertical" are used in the interest of clarity with
reference to an orientation of the base in a typical use with an
appliance positioned there-above. It is not required that the base
be provided below the appliance or that the base be maintained
exactly in this orientation. Variation of the structures may be
defined whereby portions of base are oriented vertically or at some
angle with respect to horizontal. Also, when separated from the
appliance, the base may be stored and transported in any convenient
orientation.
[0020] The shipping base 20 as illustrated is in the general form
of a rectangular frame, with front and rear rails 22, 24 and two
side rails 26, 28. Referring especially to FIG. 3, each of the
front and rear rails 22, 24 comprises an outer side wall 30, an
inner side wall 32, a first intermediate wall 34, and a second
intermediate wall 36. As shown in FIG. 3, the walls 30, 32, 34, 36
are generally upright in the typical in-use orientation, but are a
few degrees off vertical to facilitate separation of the base from
a mold. The tops of the two intermediate walls 34, 36 are joined by
a top web 40. The bottom of the outer wall 30 is joined to the
bottom of the first intermediate wall 34 by a first bottom web 42.
The bottom of the inner wall 32 is joined to the bottom of the
second intermediate wall 36 by a second bottom web 44.
[0021] As is best seen in FIGS. 1 and 2, the outer and inner walls
30, 32 and the bottom webs 42, 44 are solid. The intermediate walls
34, 36 and the top web 40 are of lattice or truss construction,
consisting of distinct bars with large spaces between them.
Compared with a solid wall or web of the same thickness, the truss
construction is lighter, and is not proportionately weaker.
[0022] Referring now to FIG. 4, when an appliance or other article
50 is mounted on the shipping base 20, the weight of the appliance
is commonly transferred to the base by feet 52 at each corner of
the appliance, as symbolized by the downward-pointing arrows in
FIG. 4. The feet 52 of the article 50 may fit into sockets 48 in
the shipping base 20. In automatic handling of the shipping base 20
and the article 50, the base may be transferred sideways off one
support, symbolized by a conveyor 54, and onto another support,
symbolized by a conveyor 56. There may be a substantial gap between
the parts of the two supports that actually support the base 20.
Thus, immediately before the second support 56 starts to support
the leading edge of the base 20, the base may overhang the first
support 54 substantially.
[0023] In this condition, the weight of the article 50 on the base
20 may be supported in large part by the end of the part of the
first support 54 that actually supports the base 20, under the base
20 between the feet 52. The contact force that supports the base at
this point is symbolized in FIG. 4 by the upward-pointing arrow 58.
The distribution of the forces 52, 56 results in a considerable
bending moment on the base 20, tending to bend its center upwards.
This places the upper parts of the front and rear rails 22, 24 in
tension, and the lower parts in compression. The tensile and
compressive stresses can be considerable.
[0024] The forces in the opposite direction are much less, because
the feet 52 are typically much closer to the outside of the base 20
than to the middle. Thus, even if the base 20 is supported at its
extreme edges, the distance between the points of support and the
points of loading by the weight force 52 is small, so the bending
moments generated are small.
[0025] As shown in FIGS. 1 and 2, in the present embodiment the
truss walls and web 40, 42, 44 of each of the front and rear rails
22, 24 comprise longitudinal bars 60 along the angles between the
top web 40 and the intermediate walls 42, 44. These longitudinal
bars 60 carry the tension loads along the upper part of the rails
22, 24. Cross bars 62 between the two longitudinal bars 60 define
with the longitudinal bars the top web 40. Upright bars 64 between
each longitudinal bar 60 and the bottom webs 42, 44, and diagonal
bars 66 between the top of one upright bar 64 and the bottom of the
next upright bar define with the longitudinal bars the intermediate
walls 34, 36.
[0026] As may be seen in FIG. 1, the top web 40 is raised above the
level of the side rails 26, 28, and the longitudinal bars 60 slope
downwards at each end to merge into the corner areas of the base
20, which are at the level of the side rails. This extra height
increases the bending strength and stiffness of the truss. The
solid inner and outer walls 32, 30 are raised to the level of the
top web 40, and protect the truss against impacts.
[0027] The bottom webs 42, 44 are joined along their outer edges to
the solid inner and outer walls 32, 30. This forms, in effect, a
solid L-section member along the bottom corners of the rail 22, 24,
which is a structure highly resistant to bending and buckling in
the regions most subject to compressive stress. The weight and
material of the rails 22, 24 is thus concentrated where it is
needed.
[0028] The embodiment shown in the drawings is intended for use in
conditions where the sort of bending moments shown in FIG. 4 are
applied only to the front and rear rails 22, 24, and the side rails
26, 28 are lower than the front and rear rails. Depending on the
intended use of a specific base 20, the trusses 40, 42, 44 could be
formed in the front and rear rails, or in all four rails. If the
trusses 40, 42, 44 are formed in all four rails, the corner regions
may also be deepened so that they rise to the height of the top
webs 40, rather than the longitudinal bars 60 being angled down to
the corners.
[0029] The present invention may be embodied in other specific
forms without departing from the spirit or essential attributes
thereof and, accordingly, reference should be made to the appended
claims, rather than to the foregoing specification, as indicating
the scope of the invention. For example, although the base has been
shown with rectangular wells or sockets 48 at all four corners,
some appliances have adjustable feet at two or all four corners. A
base intended for use with such an appliance may be provided with
sockets, such as those shown in above-mentioned U.S. Patent
Application Publication No. 2003/0057342, or with other appropriate
formations, at two or all four corners.
[0030] Also, depending on the location of the feet of the
particular appliance, some or all of the sockets may be positioned
away from the corners of the base, or along the front, back or
sides.
[0031] The outer edges of any or all of the rails 22, 24, 26, 28
may be recessed downwards as described in above-mentioned U.S.
Patent Application Publication No. 2003/0057342. In some cases,
lowering of the outer edge may be required along only some edges,
for example, it may not be required at the rear of the appliance.
Thus, any combination of raised and lowered surfaces may be
provided on the edges. Other variations are contemplated and will
be understood by those in the art.
* * * * *