U.S. patent application number 11/818077 was filed with the patent office on 2008-01-03 for shipping container.
Invention is credited to Keith S. Tabor.
Application Number | 20080000396 11/818077 |
Document ID | / |
Family ID | 38875274 |
Filed Date | 2008-01-03 |
United States Patent
Application |
20080000396 |
Kind Code |
A1 |
Tabor; Keith S. |
January 3, 2008 |
Shipping container
Abstract
A container for stackable articles includes a base assembly, a
plurality of side assemblies, a top assembly, and a plurality of
shelf assemblies. The base assembly, side assemblies, and top
assembly are preferably constructed of a multiple layer, corrugated
laminate, and are attachable to one another, defining an interior
storage space. Each shelf assembly includes a plurality of shelf
support members with a plurality of bearing portions adjacent and
integral to each shelf support member. A plurality of shelf members
are provided, wherein each shelf member is fixed about a respective
bearing portion at each end of the shelf assembly. The shelf
assemblies are secured to the sidewall assemblies, and positioned
in the storage space to engage manufactured articles, for example
sunroofs, positioned therein.
Inventors: |
Tabor; Keith S.; (Ferndale,
MI) |
Correspondence
Address: |
L.C. BEGIN & ASSOCIATES, PLLC
510 HIGHLAND AVENUE
PMB 403
MILFORD
MI
48381
US
|
Family ID: |
38875274 |
Appl. No.: |
11/818077 |
Filed: |
June 12, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60812906 |
Jun 12, 2006 |
|
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Current U.S.
Class: |
108/51.3 ;
108/55.1; 220/4.29 |
Current CPC
Class: |
B65D 2519/00452
20130101; B65D 2519/00666 20130101; B65D 19/44 20130101; B65D
2519/00502 20130101; B65D 2519/00159 20130101; B65D 2519/00621
20130101; B65D 2519/00711 20130101; B65D 2519/0082 20130101 |
Class at
Publication: |
108/051.3 ;
108/055.1; 220/004.29 |
International
Class: |
B65D 19/02 20060101
B65D019/02 |
Claims
1. A container for shipping and storing manufactured articles, said
container comprising: a container body having a base assembly and a
plurality of wall assemblies, wherein each of said plurality of
wall assemblies includes a wall panel with a lower edge attached to
said base assembly, and at least one lateral edge joined to an
adjacent wall assembly; at least one shelf assembly secured to at
least one of said wall assemblies and protruding into an interior
of said container body, said at least one shelf assembly including
a first shelf support member and a second shelf support member for
supporting at least one shelf member; a first shelf member
comprising a first end and a second end, a first tab at said first
end, a second tab at said second end, a first flap, and a first
aperture; a first bearing portion and a second bearing portion
integral to said first shelf support member for support of said at
least one shelf member, said first and second bearing portions
defining a first slot, said first tab fixed within said first slot;
and a third bearing portion and a fourth bearing portion integral
to said second shelf support member for support of said at least
one shelf member, said third and fourth bearing portions defining a
second slot, said second tab fixed within said second slot.
2. The container of claim 1 further comprising: a second shelf
assembly secured to at least one of said wall assemblies and
protruding into an interior of said container body across from said
first shelf assembly, said second shelf assembly including a third
shelf support member and a fourth shelf support member for
supporting said at least one shelf member; a second shelf member
comprising a third end corresponding to said first end of said
first shelf member, and a fourth end corresponding to said second
end of said first shelf member, a third tab at said third end, a
fourth tab at said fourth end, a second flap, and a second
aperture; a fifth bearing portion and a sixth bearing portion
integral to said third shelf support member for support of said
first shelf member, said fifth and sixth bearing portions defining
a third slot, said third tab fixed within said third slot; and a
seventh bearing portion and an eighth bearing portion integral to
said fourth shelf support member for support of said second shelf
member, said seventh and eighth bearing portions defining a fourth
slot, said fourth tab fixed within said fourth slot, wherein said
second shelf member is substantially parallel to said first shelf
member.
3. The container of claim 2 further comprising: a third shelf
member adjacent to and substantially parallel to said first shelf
member, said third shelf member comprising fifth tab at one end, a
sixth tab at a second end, and a third aperture; and a fourth shelf
member adjacent to and substantially parallel to said second shelf
member, said fourth shelf member comprising a seventh tab at one
end, an eighth tab at a second end, and a fourth aperture, wherein
the first flap of said first shelf member is fixed within the third
aperture of said third shelf member and the second flap of said
second shelf member is fixed within the fourth aperture of said
fourth shelf member.
4. A shipping container comprising: a first shelf support member
comprising a first plurality of adjacent and integral block
portions; a second shelf support member comprising a second
plurality of adjacent and integral block portions, each one of said
second plurality of block portions corresponding to one of said
first plurality of block portions; a first plurality of slots, each
one of said first plurality of slots defined between two adjacent
block portions of said first plurality of block portions; a second
plurality of slots, each one of said second plurality of slots
defined between two adjacent block portions of said second
plurality of block portions; and a first plurality of shelf
members, each shelf member comprising a first tab, a second tab, a
third tab, and an aperture, wherein each first tab is fixed within
one of said first plurality of slots, each second tab is fixed
within one of said second plurality of slots, and each third tab
mates with an aperture of an adjacent shelf member.
5. The shipping container of claim 4 wherein said block portions
are wedge portions.
6. The shipping container of claim 4 further comprising: a third
shelf support member comprising a third plurality of adjacent and
integral block portions; a fourth shelf support member comprising a
fourth plurality of adjacent and integral block portions, each one
of said fourth plurality of block portions corresponding to one of
said third plurality of block portions; a third plurality of slots,
each one of said third plurality of slots defined between two
adjacent block portions of said third plurality of block portions;
a fourth plurality of slots, each one of said fourth plurality of
slots defined between two adjacent block portions of said fourth
plurality of block portions; and a second plurality of shelf
members, each shelf member comprising a first tab, a second tab, a
third tab, and an aperture, each one of said shelf members of said
second plurality corresponding to a respective one of said first
plurality of shelf members, and said second plurality of shelf
members in substantial parallel orientation to said first plurality
of shelf members, wherein with regard to said second plurality of
shelf members, each first tab is fixed within one of said third
plurality of slots, each second tab is fixed within one of said
fourth plurality of slots, and each third tab mates with an
aperture of an adjacent shelf member.
7. A shipping container comprising: a first shelf support member
comprising a first block portion; a second shelf support member
comprising a second block portion; a first slot defined adjacent to
said first block portion on said first shelf support; a second slot
defined adjacent to said second block portion on said second shelf
support; and a shelf member comprising a first tab and a second
tab, said first tab fixed within said first slot, and said second
tab fixed within said second slot, wherein said shelf member is
fixed about said first and second block portions.
8. The shipping container of claim 7 wherein said block portions
are wedge portions.
9. The shipping container of claim 7 further comprising: a
plurality of shelf members, and, a first plurality of first tabs
wherein each of said first tabs corresponds to a respective shelf
member, a second plurality of second tabs wherein each of said
second tabs corresponds to a respective shelf member, a third
plurality of third tabs wherein each of said third tabs corresponds
to a respective shelf member, and a plurality of apertures wherein
each of said apertures corresponds to a respective shelf member, a
first plurality of adjacent block portions integral to said first
shelf support member; a second plurality of adjacent block portions
integral to said second shelf support member; a first plurality of
slots, each of said first plurality of slots defined between two
adjacent block portions of said first plurality of wedge portions;
a second plurality of slots, each of said second plurality of slots
defined between two adjacent block portions of said second
plurality of block portions wherein each first tab is fixed within
one of said first plurality of slots, each second tab is fixed
within one of said second plurality of slots, and each third tab
mates with an aperture of an adjacent shelf member.
10. A shelf assembly comprising: a first shelf support member
comprising a first block portion and a second block portion, said
first and second block portions defining a first notch
therebetween; a second shelf support member comprising a third
block portion and a fourth block portion, said third and fourth
block portions defining a second notch therebetween; and at least
one shelf member having a first end and a second end, said shelf
member comprising a first portion extending along a length of said
shelf member, said first portion comprising a first tab at said
first end, and a second tab at said second end, wherein said first
tab is fixed within said first notch and said second tab is fixed
within said second notch, and, said at least one shelf member is
fixed about the contours of said second and fourth block portions.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 60/812,906 having a filing date of Jun. 12,
2006.
TECHNICAL FIELD
[0002] The present invention relates generally to shipping and
storage containers, and more particularly to a novel shelf assembly
within such a container.
BACKGROUND OF THE INVENTION
[0003] Many different shipping container designs have been
developed over the years, some having relatively elaborate interior
shelf and article-positioning systems. One such example is found in
U.S. Pat. No. 5,667,090 to Langham et al., which discloses an
octagonal shipping container for shipping stackable manufactured
articles. The Langham container includes a plurality of attached
slotted wall panels defining an interior storage cavity. Langham
further discloses a plurality of shelf arms which project through
the slots to engage goods positioned in the storage cavity. Langham
represents one method of storing and shipping stackable
manufactured articles, in particular steering wheels. However,
there is always room for improvement. For instance, the Langham
container must be laid on its side upon a support fixture for
loading, necessarily increasing the time and effort required to
place articles into, or remove them from, the container. Further,
Langham requires a separable fastener to secure the sides of the
container.
[0004] Co-owned U.S. Pat. No. 6,832,562, herein incorporated by
reference in its entirety, describes a shipping container for
stackable articles. The container includes a base assembly, a
plurality of side assemblies, a top assembly, and a plurality of
shelf assemblies. The base assembly, side assemblies, and top
assembly are preferably constructed of a multiple layer, corrugated
laminate, and are attachable to one another, defining an interior
storage space. Each shelf assembly includes a plurality of shelf
support blocks with a plurality of face sections distributed along
a length, and a shelf flap. The shelf assemblies are secured to the
sidewall assemblies, and positioned in the storage space to engage
manufactured articles, for example sunroofs, positioned therein.
The design of this container provided certain advantages including
the elimination of wood augmentation in the container, thereby
meeting customer requirements that mandated the elimination of wood
due to infestation concerns. Furthermore, the likelihood of damage
to articles shipped within this container was substantially reduced
due to the enhanced strength of the shelf assemblies. The load time
of sunroofs, for example, was also substantially reduced given the
prefabricated shelf assemblies within this container. Nevertheless,
continued goals include providing even stronger shelf assemblies,
and reducing the manufacturing complexity associated with shipping
containers.
[0005] It is thus desirable to construct a container for stackable
goods that can be easily assembled and loaded, yet is strong and
durable. The present invention addresses one or more of the
limitations or problems associated with the related art.
SUMMARY OF THE INVENTION
[0006] In one aspect, the present invention provides a container
for shipping and storing manufactured articles. The container
includes a container body with a base assembly and a plurality of
walls. Each of the walls includes a lower edge attached to the base
assembly and at least one lateral edge joined to an adjacent wall
panel. At least one shelf assembly, and preferably a plurality of
shelf assemblies, is also provided which are secured to the wall
assemblies and protrude into an interior of the container body. A
first shelf assembly includes a first shelf support member and a
second shelf support member for structural support of the shelf
assembly. Each shelf support member includes at least a first block
portion or shelf bearing portion, and a second block portion or
shelf bearing portion integral thereto, wherein the first and
second block portions together define a first recessed slot or
notch therebetween. At least one shelf member extends between the
first and second shelf support members, thereby forming a shelf
extending substantially across the interior of the container. A
preferred embodiment includes two shelf assemblies containing more
than two block portions, thereby accommodating a plurality of shelf
members.
[0007] Stated another way, the present invention includes a
container including at least one shelf assembly and preferably a
plurality of shelf assemblies. Each shelf assembly includes a first
shelf support member containing a first plurality of adjacent and
integral block portions and a second shelf support member
containing a second plurality of adjacent and integral block
portions. Each one of the second plurality of block portions
corresponds to one of the first plurality of block portions. A
first plurality of slots is contained within the first shelf
support member wherein each slot is defined between two sequential
or adjacent block portions of said first plurality of block
portions for support of a shelving member described below. A second
plurality of slots is contained within the second shelf support
member wherein each slot is defined between two sequential or
adjacent block portions of said first plurality of block portions
for support of a shelving member described below. A first plurality
of shelf members is provided wherein each shelf member includes a
first tab, a second tab, a third tab, and an aperture, wherein each
first tab is fixed within a respective one of the first plurality
of slots, each second tab is fixed within a respective one of the
second plurality of slots, and each third tab mates with an
aperture of an adjacent shelf member.
[0008] Other shelf assemblies may be formed in the same manner and
employed within the interior of the shipping container. In general,
containers formed in accordance with the present invention will
preferably contain two shelf assemblies on opposite sides of the
shipping container interior.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a partial exploded view of one embodiment in
accordance with the present invention;
[0010] FIG. 2 is a partial exploded view of one embodiment in
accordance with the present invention;
[0011] FIG. 3 is a partial exploded view of one embodiment in
accordance with the present invention;
[0012] FIG. 4 is an exploded view of the shelf assemblies in
accordance with the present invention;
[0013] FIG. 5 is an exploded view of the shelf assemblies in
conjunction with the wall assemblies;
[0014] FIG. 6 is a plan view of a laminate of multiple layers of
corrugated material for forming shelf support members in accordance
with the present invention.
[0015] FIG. 7 is a perspective view of a shelf support member in
accordance with the present invention;
[0016] FIG. 8 is a plan view of a shelf member in accordance with
the present invention;
[0017] FIG. 9 is a partial exploded view of one embodiment in
accordance with the present invention;
[0018] FIG. 10 is a partial exploded view of one embodiment in
accordance with the present invention;
[0019] FIG. 11 is a partial exploded view of one embodiment in
accordance with the present invention;
[0020] FIG. 12 is a partial exploded view of one embodiment in
accordance with the present invention;
[0021] FIG. 13 is an exploded view of one container in accordance
with the present invention; and
[0022] FIG. 14 is a partial exploded view of one embodiment in
accordance with the present invention.
DETAILED DESCRIPTION
[0023] FIGS. 1-14 illustrate one embodiment of a container 10 for
use in storing, shipping, and protecting any of a variety of
substantially flat components or sub-assemblies (for example,
sunroofs mountable in automobile assemblies.) In the embodiment
disclosed herein, unless otherwise stated, components of the
container are formed using known processes from one or more
laminated layers of a corrugated material, such as a corrugated
board or paper material. However, the use of alternative materials,
such as wood, polymers, or metals is also contemplated. In
addition, unless otherwise stated, known methods of joining
together pieces of corrugated material, such as nailing, gluing or
adhesive application, stapling, bump stitching, and other known
methods are all contemplated for use in assembling the container
and components described herein.
[0024] FIG. 1 illustrates a base 12 of the container 10. Base 12
comprises a frame portion 12a (for example, a corrugated laminate
pallet, or a wooden shipping pallet) and a container bottom portion
12b. Bottom portion 12b has a body 12c and a plurality of flaps 12d
formed along edges of body 12c. Bottom portion 12b may also be
formed from a sheet of corrugated material cut to form flaps 12d,
which are then folded upward and secured to each other as shown to
form a tray-like structure. The bottom portion is then nailed,
glued, stapled, or otherwise secured to frame portion 12a.
[0025] Referring to FIG. 2, a body portion 14 is positioned and
secured within base portion 12. Body portion 14 has a rear wall
portion 14a and a plurality of side flaps 14b and base flaps 14c
formed along edges of rear wall portion 14a. Body portion 14 may be
formed from a sheet of corrugated material cut to form side flaps
14b and base flaps 14c which are then folded as shown and secured
to base portion body 12c and to base portion flaps 12d.
[0026] Referring to FIG. 3, a rear stop portion 16 is secured to
rear wall portion 14a to provide a cushion or shock absorbing
member for articles inserted into and stored in container 10. Rear
stop portion 16 may also occupy dead space between rear wall
portion 14a and edges of the components stored in the container,
thereby aiding in immobilization of the components stored in the
container. Rear stop portion 16 may be formed from a sheet of
corrugated material cut to size and folded as shown to produce a
shock-absorbing wedge 16a therein. The rear stop portion is then
positioned and secured to rear wall portion 14a of body portion 14.
Alternatively, foam or other padding may be secured to rear wall
portion 14a of body portion 14 to provide the desired cushioning
effect.
[0027] Referring to FIGS. 5-8, a left wall 20 and right wall 22 of
the container are provided for supporting the components to be
stored and shipped in the container. Walls 20, 22 each include
respective wall portions 20a, 22a, a plurality of shelf support
portions 24 secured to wall portions 20a, 22a, and a plurality of
shelf portions 18 secured to wall portions 20a, 22a and supported
by shelf support portions 24.
[0028] FIG. 6 is a plan view of a laminate of multiple layers of
corrugated material for use in forming shelf support portions 24 of
the present invention, shown prior to cutting of the shelf support
portions. FIG. 7 is a perspective view showing a laminated shelf
support portion 24 of the container 10 of the present invention cut
to shape. Referring to FIGS. 6 and 7, shelf support members or
portions 24 may be produced by forming a laminate of multiple
layers of corrugated material and die-cutting or otherwise cutting
the laminate to the achieve the desired profile or shape shown in
FIG. 7. For example, using the laminate arrangement of FIG. 6,
eight shelf support portions may be cut from a single laminate.
[0029] The laminate may be formed to any desired thickness, subject
to any process limitations, to provide a desired degree of strength
to the shelf support member. As seen in FIGS. 6 and 7, in one
embodiment, shelf support portions 24 includes a plurality of
bearing portions 24a, with a slot 24b formed between adjacent ones
of bearing portions 24a. In the embodiment shown, bearing portions
have a saw-tooth configuration or wedge shape which provides a
relatively strong base in the region of the bearing portion which
is under the greatest mechanical stresses, due to the weight of the
part being supported. Slots 24b are dimensioned (in conjunction
with tabs 18f on shelf portions 18, described in greater detail
below) so as to provide an interference fit with tabs 18f inserted
therein, thereby providing additional structural stability to the
container.
[0030] Referring to FIG. 8, shelf portions 18 are provided which
span a distance between adjacent shelf support portions 24, thereby
providing substantially continuous support of the stored components
along the lengths thereof when they are positioned and secured
within the container. Shelf portions 18 may be formed as shown in
FIG. 8, wherein one or more sheets of corrugated material are cut
to the shape shown an then cut down the center thereof (along line
18a) to form two shelf members 18.
[0031] In one method of assembly of walls 20, 22, shelf portions 18
are folded along folds 18b and 18c (FIG. 8), to substantially
conform to the profile of bearing portions 24a (FIGS. 6 and 7) of
shelf support portions 24. Successive ones of shelf members 18 are
then connected or daisy-chained together by fixing or inserting tab
18d from one shelf portion 18 into slot or aperture 18e of an
adjacent shelf portion 18, thereby creating a continuous,
accordion-like shelf structure. "Fixing" may mean simply inserting
the tab or flap 18d into the corresponding aperture 18e of the next
adjacent shelf member 18. Or, "fixing" may mean to glue or
otherwise ensure that flap 18d is snugly fit within aperture 18e of
the subsequent or adjacent shelf member 18. This shelf structure
may be easily positioned to follow the contours defined by shelf
support bearing portions 24a, by bending tabs 18f out of the plane
of the shelf section on which they are formed, and inserting tabs
18f into corresponding slots 24b formed or defined between adjacent
bearing portions 24a of shelf support portions 24. Tabs 18f are
formed in positions along shelf portions 18 such that insertion of
the tabs into slots 24b forces the shelf portion structure to bend
according to the contours of the shelf support portion. When all of
tabs 18f have been inserted into associated slots 24b, the tabs are
bent back into the plane in which they were originally formed,
during which a formed end of each shelf portion 18 wraps over a
corresponding surface of a bearing member 24a of shelf support
portion 24. Shelf portions 18 are now supported at each end thereof
by a bearing portion 24a. Shelf support portions 24 may then be
positioned along wall portions 20a, 22a and glued or otherwise
secured to the wall portions.
[0032] Other assembly methods or sequences are also contemplated.
For example, shelf support portions 24 may be secured to wall
portions 20a, 22a prior to attachment of shelf portions 18 thereto.
When walls 20, 22 are complete, each wall is secured to a
corresponding side flap 14b of body portion 14.
[0033] FIG. 14 shows a front 30 of the container. Front 30
comprises a body 30a and a plurality of flaps 30b formed along
edges of body 30a. Front 30 may be formed from a sheet of
corrugated material cut to form flaps 30b, which are then folded
and secured to each other as shown so as to wrap over edges of
walls 20, 22. A shock absorbing positioning member such as rear
stop portion or a foam padding, similar to that provided along rear
wall 14a, may be secured to an interior surface of front 30.
[0034] FIG. 9 shows a top 32 of the container. Top 32 comprises a
body 32a and a plurality of flaps 32b formed along edges of body
32a. Top 32 may be formed from a sheet of corrugated material cut
to form flaps 32b, which are then folded and secured to each other
as shown to form a top which may be wrapped over upper edges of
walls 20, 22 and body portion 12.
[0035] FIGS. 10-13 show various stages in the final assembly of the
shipping container 10.
[0036] It should be understood that the present description is for
illustrative purposes only, and should not be interpreted to limit
the scope of the present invention in any way. Thus, those skilled
in the art will appreciate that various modifications to the
disclosed embodiments might be made without departing from the
intended spirit and scope of the present invention, which should be
given the full breadth of the claims and any and all equivalents
thereof. For example, a preferred embodiment has been illustrated
as having four walls, however, the shelf assembly that is an object
of the present invention might find application in three sided or
many sided containers, or even as a separate stand alone shelf. As
discussed above, substantial variations might be made to the number
and positioning of shelf assemblies within the container, allowing
goods of differing shapes and sizes to be positioned in the same
container, for instance, sunroofs for different vehicle models.
Further, the presently disclosed shelf assembly could find
application in containers designed not for shipping, but for
permanent storage or display of manufactured articles. Other
objects and features of the present invention will be evident upon
an examination of the attached drawing figures and appended
claims.
* * * * *