U.S. patent application number 12/790432 was filed with the patent office on 2010-11-18 for reusable pallet container.
Invention is credited to Richard Cooke, Rich Glover, Al Hoag, Bill Howard, Dino Lanno, Ronald Price, Richard Rudyk, Markus Schmidt, Andy Scott, Evan Taylor.
Application Number | 20100288664 12/790432 |
Document ID | / |
Family ID | 43067649 |
Filed Date | 2010-11-18 |
United States Patent
Application |
20100288664 |
Kind Code |
A1 |
Glover; Rich ; et
al. |
November 18, 2010 |
Reusable pallet container
Abstract
A reusable pallet container is disclosed. According to one
embodiment of the disclosure, a pallet container for holding
vehicle windshields for storage, transportation or otherwise is
disclosed. The pallet container includes a frame structure defining
a base, and a periphery, wherein one or more side restraints are
provided to be mounted on-board the pallet container to inhibit
movement of windshields internally of the pallet container, wherein
at least one of said one or more side restraints comprises a
flexible fluid containing device.
Inventors: |
Glover; Rich; (Rocky Mount,
NC) ; Hoag; Al; (Rocky Mount, NC) ; Rudyk;
Richard; (Toronto, CA) ; Lanno; Dino;
(Blacklick, OH) ; Howard; Bill; (Halifax, NC)
; Cooke; Richard; (Wigston, GB) ; Price;
Ronald; (Rocky Mount, NC) ; Scott; Andy;
(Roanoke Rapids, NC) ; Schmidt; Markus; (Kingston
upon Thames, GB) ; Taylor; Evan; (Conway,
NC) |
Correspondence
Address: |
ICE MILLER LLP
ONE AMERICAN SQUARE, SUITE 3100
INDIANAPOLIS
IN
46282-0200
US
|
Family ID: |
43067649 |
Appl. No.: |
12/790432 |
Filed: |
May 28, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11857281 |
Sep 18, 2007 |
7784613 |
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12790432 |
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10759944 |
Jan 16, 2004 |
7270236 |
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11857281 |
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60442719 |
Jan 27, 2003 |
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Current U.S.
Class: |
206/386 |
Current CPC
Class: |
B65D 85/48 20130101;
B65D 81/052 20130101; Y02W 30/80 20150501; B65G 49/062 20130101;
B65D 2585/6882 20130101; Y02W 30/807 20150501; B65D 19/44
20130101 |
Class at
Publication: |
206/386 |
International
Class: |
B65D 19/02 20060101
B65D019/02 |
Claims
1. A pallet container for holding vehicle windshields for storage,
transportation or otherwise, the pallet container comprising a
frame structure defining a base, and a periphery, wherein one or
more side restraints are provided to be mounted on-board the pallet
container to inhibit movement of windshields internally of the
pallet container, wherein at least one of said one or more side
restraints comprises a flexible fluid containing device.
2. The pallet container according to claim 1, wherein said flexible
fluid containing device of said at least one of said side
restraints is positioned at opposing ends of the pallet
container.
3. The pallet container according to claim 2, wherein said flexible
fluid containing device of said at least one of said side
restraints comprises an inflatable flexible walled device.
4. The pallet container according to claim 3, wherein said
inflatable flexible walled device comprises an air bag.
5. The pallet container according to claim 1, wherein at least one
of said one or more side restraints is secured to said frame
structure of said pallet container.
6. A pallet container for holding vehicle windshields for storage,
transportation or otherwise, the pallet container comprising a
frame structure defining a base, and a periphery, wherein the frame
structure is expandable from a minimum dimension windshield
containing configuration to a maximum dimension windshield
containing configuration; wherein in the maximum dimension
containing configuration the pallet container is extended in both
height and in length when compared to the minimum dimension
configuration.
7. The pallet container according to claim 6, wherein said pallet
container is collapsible from a windshield containing configuration
to a stowed configuration.
8. The pallet container according to claim 7, wherein said pallet
container has opposing side frames arranged to be hinged or pivoted
to fold down from an erect condition to a collapsed condition.
9. The pallet container according to claim 8, wherein when said
pallet container is in the collapsed condition, said opposing side
frames are positioned laying adjacent the base of said pallet
container.
10. The pallet container according to claim 8, wherein said pallet
container comprises a connecting frame extending between said
opposing side frames, the connecting frame arranged to be hinged or
pivoted to fold down from an erect condition to a collapsed
condition.
11. The pallet container according to claim 8, wherein said
opposing side frames are extendible in effective length to vary the
height of the side frames.
12. The pallet container according to claim 11, wherein the side
frames comprise telescoping side frame elements.
13. The pallet container according to claim 12, wherein said side
frame elements extend in a longitudinal direction of the pallet
container to connect the opposing side frames, wherein said side
frame elements are extendible in effective length to vary the
length of the pallet container.
14. The pallet container according to claim 6, wherein the pallet
container comprises stacking formations enabling like pallet
containers to be stacked one on top of another.
15. The pallet container according to claim 6, further comprising
one or more side restraints that are mounted on-board the pallet
container to inhibit movement of windshields internally of the
pallet container, wherein a said side restraint comprises a
flexible fluid containing device.
16. A pallet container for holding vehicle windshields for storage,
transportation or otherwise, the pallet container comprising a
frame structure defining a base, and a periphery, wherein the
pallet container is collapsible from a windshield containing
configuration to a stowed configuration, and comprises: opposing
side frames arranged to be hinged or pivoted to fold down from an
erect condition to a collapsed condition; and, a connecting frame
extending between the opposing side frames, the connecting frame
arranged to be hinged or pivoted to fold down from an erect
condition to a collapsed condition.
17. The pallet container according to claim 16, wherein in the
collapsed condition the opposing side frames and the connecting
frame are positioned laying adjacent the base of the pallet
container.
18. The pallet container according to claim 17, wherein the
connecting frame and opposing side frames have formations arranged
to complementarily engage one another in the pallet container
erected configuration and be releasable to disengage permitting
re-orientation to the collapsed configuration.
19. The pallet container according to claim 16, wherein the side
frames comprise telescoping side frame elements.
20. The pallet container according to claim 19, wherein said side
frame elements extend in a longitudinal direction of the pallet
container to connect the opposing side frames, wherein said side
frame elements are extendible in effective length to vary the
length of the pallet container.
Description
[0001] This application is a continuation-in-part of co-pending
U.S. patent application Ser. No. 11/857,281, which is a divisional
application of U.S. patent application Ser. No. 10/759,944, now
U.S. Pat. No. 7,270,236, which claims the benefit under 35 U.S.C.
119(e) of Provisional Application Ser. No. 60/442,719, filed on
Jan. 27, 2003. Each application and patent mentioned above is fully
incorporated herein by reference.
BACKGROUND
[0002] The present application relates to a container, particularly
a re-usable pallet container such as a metal pallet that can be
used for packing, storage and shipping of items, particularly
fragile items such as vehicle windshields.
[0003] A collapsible, re-usable windshield pallet for packing,
storage, and shipping of windshields of varying shapes and sizes is
disclosed in, for example, U.S. Pat. No. 7,270,236. It has been
recognized that it is an advantage to be able to ship windshields
of varying sizes in a single container and also to ensure that the
container is collapsible to enable return transportation of the
container in the collapsed form (when no windshields are being
shipped), in order to minimize transport volume and potentially
reduce shipping costs. The containers can also be stored in
collapsed form in distribution centers and stockyards when not
being used to contain windshields. U.S. Pat. No. 7,270,236 also
identifies the need to use lateral restraints to prevent the
windshields from moving in the longitudinal direction of the
pallet.
[0004] Partially collapsible or foldable steel pallets are known
for use in place of wood pallets in shipping heavy and awkward
articles such as automobile windshields. Steel pallets are very
durable, allowing for prolonged use. Moreover, partially
collapsible pallets allow for reduced shipping volume, decreasing
the cost of relocating empty pallets for reuse. Accordingly, it is
known generally to use partially collapsible steel pallets to ship
breakable goods, such as automobile windshields.
[0005] The shipment of breakable goods presents unique challenges
in the design of reusable pallets. For example, if a pane of glass
is not properly secured within the pallet, unacceptable levels of
breakage occur in shipment. Accordingly, it is known to use dunnage
when shipping windshields. "Dunnage" is simply packing material
which is added to the pallet so as to make the shipped material
more secure. Of course, the addition of dunnage to the pallet takes
time, and increases the potential for breakage when improperly
performed. Moreover, the need for dunnage increases the cost of
shipping. All of these problems are exacerbated when a partial
pallet (a pallet that is not completely filled) is to be
shipped.
[0006] It is also known to design a pallet so as to provide support
at a plurality of locations when shipping a pane of glass. U.S.
Pat. No. 5,154,310 to Massey is an example of this type of pallet.
In accordance with the '310 patent, an end nestable stackable
container is provided with a means to firmly contain material being
shipped. Four points of contact are provided for the material to be
shipped. The '310 patent accomplishes this by providing hold down
arms which can be pivoted over the top of the material being
shipped, so as to provide contact along the top edge of the
material. Contact on two sides of the material being shipped is
provided by a side stabilizing mechanism. The fourth point of
contact is along the bottom of the material. The device disclosed
in the '310 patent is useful when shipping empty pallets. However,
because the pallet is only partially collapsible, which allows the
empty pallets to be nested, the number of pallets which can be
safely stacked before the stack starts to lean is limited.
[0007] The device disclosed in the '310 patent is also useful when
shipping a number of panes which are of a uniform shape and size.
However, in certain applications it would be advantageous to ship
glass of differing shapes and sizes within a single pallet. For
example, the secondary windshield market provides replacement
windshields for all makes and models of vehicles. It is impractical
for retail stores to maintain a supply of every shape and size
windshield for every make and model of vehicle. Thus, the secondary
windshield market has evolved into a make-to-order market. In a
make-to-order market, when a windshield of a particular size is
needed, an order is placed to a manufacturing facility. The
facility then manufactures a replacement windshield. The
replacement windshield is next packaged, along with other
windshields, and transported to a distribution center, for eventual
shipment to the location which placed the initial order.
[0008] Obviously, a number of alternative distribution models
exist. For example, certain sized windshields may be so commonly
required as replacements that a certain level of inventory is
desired at the distribution center. Alternatively, more or fewer
distribution points may be included in a particular distribution
model. Regardless of the model, however, it is advantageous to be
able to place windshields of various sizes and shapes on a single
pallet. The presence of windshields of non-uniform shape or size on
a single pallet is called a "mixed pallet." Use of a mixed pallet
allows for optimization of the use of pallet volume when shipping
windshields, so that fewer pallets are required. As the number of
pallets is reduced for a given number of windshields, the overall
required shipping volume and weight is reduced. When using steel
pallets, the reduced weight can be significant. Of course, the
reduced number of pallets also results in cost savings when
returning the pallets to the manufacturing facility for reuse.
[0009] Typical variation in windshield shape and size is discussed
with reference to FIGS. 12-14. FIG. 12 is a perspective view of a
windshield. As shown in FIG. 12, windshield 1200 is curved from
corner 1202 to corner 1204. Windshield 1200 is also curved between
upper midpoint 1206 and lower midpoint 1208. This is shown more
clearly in FIG. 14 which is discussed below.
[0010] Referring now to FIG. 13, a front view of windshield 1200 is
shown. Also shown in FIG. 13 is a front view of windshield 1210,
which is located behind windshield 1200. As is clear from FIG. 13,
windshield 1200 is both longer and taller than windshield 1210.
[0011] FIG. 14 is a side view of windshield 1200 and windshield
1210 in a substantially upright position. Front face 1212 (outside
when installed in a vehicle) of windshield 1200 and front face 1214
of windshield 1210 are curved. Additionally, windshield 1200 and
windshield 1210 are curved from end to end. This is shown in FIG.
15, which is a top plan view of windshield 1200 and windshield
1210.
[0012] Thus, ear 1216 and ear 1218 of windshield 1210 are located
behind the midpoint of the rear face of windshield 1210, which is
shown in FIG. 14 as dashed line 1230. Similarly, ear 1218 and ear
1220 of windshield 1200 are located behind the midpoint of the rear
face of windshield 1200, which is shown in FIG. 14 as dashed line
1232. As is apparent from FIG. 14, ear 1220 of windshield 1200
extends farther back from dashed line 1232 than ear 1216 of
windshield 1210 extends back from dashed line 1230.
[0013] Since it is desirable to maintain all of the windshield
within the protective box or envelope defined by the outer
boundaries of the pallet to minimize breakage, and since
windshields are typically shipped in a generally upright position,
a pallet used to ship windshields of multiple heights must be high
enough to enclose the tallest windshield to be shipped. Obviously,
when shipping shorter windshields, this results in a pallet of
unnecessary weight and volume, increasing shipping costs.
[0014] Moreover, in order to ensure the ears of the windshield (the
outermost ends) are maintained within the envelope of the pallet,
it is known to use a stop: A "stop", as used herein, is an object
that protrudes into the pallet envelope to maintain spacing between
the windshield and the end of the pallet. The stop protrudes into
the pallet and contacts the rear face of the windshield. Because
windshields are of varying curvature and length, the distance the
stop must protrude into the envelope of the pallet varies.
Obviously, sizing the stops to ensure the windshields of greatest
curvature and length are maintained within the envelope of the
pallet results in wasted space when windshields of lesser curvature
and length are shipped. This decrease in shipping density of the
pallet, can result in more pallets being required to ship a given
number of windshields. While some present art systems allow for
adjustable stops, these systems include a number of moving parts,
and take a significant amount of time to adjust.
[0015] Another problem caused by the curvature of windshields is
that the center of gravity of the pallet will not be the volumetric
center of the pallet. Therefore, when the windshields are secured
within a pallet, a torque is created, This is typically not a
problem when a single pallet is considered, or when the pallet is
not collapsible. However, when stacking collapsible pallets wherein
an upright post is inserted into a holder, the torque will tend to
unseat the post from the holder. Thus, stacked pallets can develop
a lean.
[0016] An additional problem is presented because of the varying
lengths of present day windshields. Typically, a restraint is
incorporated on each side of a pallet to maintain loaded
windshields within the envelope of the pallet. A "restraint", as
used herein, is an object that maintains a windshield within the
envelope of the pallet at the sides of the pallet. Positioning the
restraints to allow for the shipment of the longest windshield
expected to be shipped, results in an undesirably large lateral
area within which a windshield is allowed to move before being
laterally constrained. Although it is known to provide adjustable
lateral restraints, these restraints include a number of parts
which can be misplaced and/or are time consuming to adjust.
[0017] It is desirable, therefore, to provide a device which allows
for shipment of vehicle replacement glass of non-uniform shape
and/or size while minimizing breakage of the glass in shipping. It
is further desired that the device minimize the required amount of
dunnage, and be simple to use. Moreover, it is desired that the
device be of simple, lightweight and inexpensive construction. It
is desired that the pallet be stackable even when empty and
collapsed. It is also desired to have a shipping pallet that is
versatile enough to ship tall windshields without wasting weight
and volume when shipping short windshields. It is further desirable
to provide stops which use a minimum number of parts and which can
be quickly and easily changed to the proper distance of protrusion
into the pallet. Moreover, it is desired to have a collapsible
pallet that will not lean when stacked. Additionally, it is desired
to provide a restraint which is quickly and easily repositioned to
a lateral position dictated by the longest windshield in the pallet
being shipped.
SUMMARY
[0018] According to a first aspect, the present invention provides
a pallet container for holding vehicle windshields for storage,
transportation or otherwise, the pallet container comprising a
frame structure defining a base, and a periphery, wherein one or
more side restraints are provided to be mounted on-board the pallet
to inhibit movement of windshields internally of the pallet
container, wherein a said side restraint comprises a flexible fluid
containing device. It is preferred that respective flexible fluid
containing side restraint devices are positioned at opposing ends
of the pallet container. In one embodiment, the side restraint
devices comprise air bags. The side restraint devices are
preferably secured to the frame structure of the pallet
container.
[0019] According to an alternative aspect, the present invention
provides a pallet container for holding vehicle windshields for
storage, transportation or otherwise, the pallet container
comprising a frame structure defining a base, and a periphery,
wherein the frame structure is expandable from a minimum dimension
windshield containing configuration to a maximum dimension
windshield containing configuration; wherein in the maximum
dimension containing configuration the pallet container is extended
in both height and in length when compared to the minimum dimension
configuration. It is preferred that, in addition to being
expandable from a minimum dimension windshield containing
configuration to a maximum dimension windshield containing
configuration; the pallet container is also collapsible from a
windshield containing configuration to a stowed configuration not
suitable for containing windshields but convenient for
transportation or storage of pallet containers, In a preferred
realization, the pallet container has opposing side frames arranged
to be hinged or pivoted to fold down from an erect condition to a
collapsed condition. Beneficially, in the collapsed condition the
opposing side frames are positioned such that they are laying
adjacent the base of the pallet container.
[0020] It is preferred that the pallet container has a connecting
frame extending between the opposing side frames, the connecting
frame arranged to be hinged or pivoted to fold down from an erect
condition to a collapsed condition. In a preferred realization of
the present invention, the pallet container has opposing side
frames which are extendible in effective length to vary the height
of the side frames. The side frames may comprise telescoping side
frame elements permitting the height of the pallet container to be
varied.
[0021] Beneficially, the pallet container frame structure includes
connecting frame elements extending in a longitudinal direction of
the pallet container to connect the opposing side frames, the
connecting frame elements preferably being extendible in effective
length to vary the length of the pallet container. It is preferred
that the pallet includes stacking formations enabling like pallets
to be stacked one on top of another.
[0022] According to an alternative aspect, the present invention
provides a pallet container for holding vehicle windshields for
storage, transportation or otherwise, the pallet container
comprising a frame structure defining a base, and a periphery,
wherein the pallet container is collapsible from a windshield
containing configuration to a stowed configuration, and comprises
opposing side frames arranged to be hinged or pivoted to fold down
from an erect condition to a collapsed condition and a connecting
frame extending between the opposing side frames, the connecting
frame arranged to be hinged or pivoted to fold down from an erect
condition to a collapsed condition. It is preferred that the
connecting frame and opposing side frames have formations arranged
to complementarily engage one another in the pallet container
erected configuration and be releasable to disengage permitting
re-orientation to the collapsed configuration.
[0023] According to an alternative aspect, the present invention
provides a side restraint system for a pallet container for holding
vehicle windshields for storage, transportation or otherwise, the
side restraint system comprising one or more flexible fluid
containing devices mounted on-board the pallet to inhibit movement
of the windshields.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of one embodiment of a reusable
windshield pallet.
[0025] FIG. 2 is a perspective fragmentary view showing a
disassembled stub and post of the pallet of FIG. 1.
[0026] FIG. 3 is a perspective fragmentary view of the stub and
post of FIG. 2 in an assembled configuration.
[0027] FIG. 4A is a side plan view of a side frame of the pallet of
FIG. 1.
[0028] FIG. 4B is an end cross-sectional view of the side frame of
FIG. 4A taken along line B-B in FIG. 4A.
[0029] FIG. 5A is a top plan view of a front support bar.
[0030] FIG. 5B is a rear plan view of the front support bar of FIG.
5A.
[0031] FIG. 6A is a top plan view of a rear support bar.
[0032] FIG. 6B is a rear plan view of the rear support bar of FIG.
6A,
[0033] FIG. 7A is a perspective view of a longitudinal member of
the pallet of FIG. 1.
[0034] FIG. 7B is a perspective view of an insert for the
longitudinal member of FIG. 7A.
[0035] FIG. 7C is a perspective view of the insert of FIG. 7B in
the longitudinal member of FIG. 7A.
[0036] FIG. 8 is a perspective view of an extension.
[0037] FIG. 9 is a side plan view of a transverse member of the
pallet of FIG. 1 and a partial cutaway view of a side
restraint.
[0038] FIG. 10 is a plan view of the side restraint of FIG. 9.
[0039] FIG. 11 is a perspective view of the lower front stop of the
pallet of FIG. 1.
[0040] FIG. 12 is a perspective view of a windshield.
[0041] FIG. 13 is a front view of the windshield of FIG. 12 and a
second windshield.
[0042] FIG. 14 is a side view of the windshields of FIG. 13.
[0043] FIG. 15 is a top plan view of the windshields of FIG.
13.
[0044] FIG. 16 is a perspective view of one embodiment of a
reusable windshield pallet loaded with windshields.
[0045] FIG. 17 is a perspective view of a reusable windshield
pallet in a folded compact configuration.
[0046] FIG. 18 is a perspective view of three folded reusable
windshield pallets stacked together.
[0047] FIG. 19 is a perspective view from the front of a pallet
container in accordance with one embodiment of the present
invention.
[0048] FIG. 20 is a perspective view of the upper rear cross frame
connecting to the side frame of FIG. 19.
[0049] FIG. 21 is a perspective view of the connection to a side
frame stub of the forward lower cross frame of FIG. 19.
[0050] FIG. 22 is a perspective view from an end of the pallet
container of FIG. 19.
[0051] FIG. 23 is a plan view of the pallet container of FIG.
19.
[0052] FIG. 24 is a side view of the pallet container of FIG. 19
showing the ability to vary the size of the pallet container in the
erected condition.
[0053] FIG. 25 is an end view of the pallet container of FIG.
24.
[0054] FIG. 26 is an end view showing two collapsed pallet
containers stacked one on top of another in accordance with one
embodiment of the present invention,
[0055] FIGS. 27A to 27C are end, plan, and side views,
respectively, showing the seat attached to the boss for receiving
the tube frames in accordance with one embodiment of the present
invention.
[0056] FIGS. 28A and 28B are plan and side views, respectively, of
a tube frame in accordance with one embodiment of the present
invention.
[0057] FIG. 29 is a perspective view from the front of a pallet
container in accordance with an alternative embodiment of pallet
container in accordance with the present disclosure.
[0058] FIG. 30 is a side end view of the embodiment of FIG. 29.
[0059] FIG. 31 is a detail view of the side end frame of FIG.
30.
[0060] FIG. 32 is perspective detailed view of a part of the
container according to the alternative embodiment showing an
adaptation for aiding loading of the pallet container.
DETAILED DESCRIPTION OF THE INVENTION
[0061] Referring to FIG. 1, a reusable windshield pallet is
described. Pallet 100 comprises frame 102. The front of pallet 100
is indicated by reference letter F. The rear of pallet 100 is
indicated by reference letter R. Frame 102 comprises bars 101, 103,
105 and 107, arranged in a substantially rectangular configuration.
Stubs 104, 106, 108 and 110 are attached to frame 102 at the
corners defined by bars 101, 103, 105 and 107. In this embodiment,
stub 104 is welded to bar 105 and bar 107, stub 106 is welded to
bar 103 and bar 105, stub 108 is welded to bar 101 and bar 103, and
stub 110 is welded to bar 101 and bar 107.
[0062] Side frame 112 comprises post 114 and post 116. Post 114 and
post 116 are engaged with stubs 104 and 110 respectively. Thus,
post 114 and post 116 are the upper sections of rigid members
extending from frame 102, and stubs 104 and 110 are the lower
sections of rigid members extending from frame 102. Side frame 118
comprises posts 120 and 122. Posts 120 and 122 are similarly
engaged with stubs 106 and 108 respectively so as to provide rigid
members extending from frame 102. Rear support bar 124 is removably
attached to post 116 and post 122. Front support bar 126,
comprising front stop 128, is removably attached to post 114 and
post 120.
[0063] Pallet 100 further comprises longitudinal members 130 and
132, each of which are welded to bars 101 and 105. Transverse
members 134 and 136 are connected between longitudinal member 130
and 132, respectively, and frame 102 of pallet 100. Specifically,
transverse member 134 is welded to bar 107 and longitudinal member
130, and transverse member 136 is welded to bar 103 and
longitudinal member 132. Alternative longitudinal and transverse
members are discussed more fully below, Locking bar 138 is located
at the forward end of pallet 100 between longitudinal members 130
and 132, Rack 140 is provided at the rear of pallet 100 and lower
front stop 142 is located on the front of frame 102.
[0064] Referring now to FIG. 2, the mechanism allowing side frame
112 and side frame 118 to be collapsed or folded is described. FIG.
2 is a perspective view showing stub 104 and post 114 disassembled.
Stub 104 comprises slot 200 and pin 202. Flared end 206 of stub 104
allows for stacking of pallet 100 as it is sized to receive the
upper end of a stub on a second pallet, the upper end of a post on
a second pallet, and the upper end of an extension, as discussed
below. Post 114 includes slot 208.
[0065] When fully assembled, pin 202 is located within slot 208 and
the portion of post 114 below slot 208 is located within stub 104.
Thus, when post 114 is fully inserted into stub 104, pin 202 abuts
the top of slot 208. From the fully inserted position, post 114 may
be raised such that pin 202 abuts the bottom of slot 208. With post
114 so raised, post 114 may be rotated in the direction of arrow
211, so as to lie substantially in the plane of frame 102.
Conversely, if post 114 is laying substantially in the plane of
frame 102, post 114 can be rotated in the direction opposite arrow
211 into an upright position. Once in an upright position, post 114
may be lowered straight down into stub 104 as slot 208 slides past
pin 202, until pin 202 abuts the top of slot 208. A similar pin and
slot arrangement is used for post 116 and stub 110. Side frame 118
has a similar configuration.
[0066] Referring now to FIG. 3, post 114 is shown fully inserted
into stub 104. Also shown in this figure is a means for maintaining
post 114 in a fixed relationship with stub 104, Latch 210 is
pivotably connected to post 114 at pivot 212. In this embodiment,
pin 202 protrudes beyond the wall of stub 104. Thus, when post 114
is inserted into stub 104, latch 210 of post 114 engages the
protruding portion of pin 202. Thus, post 114 cannot be moved in an
upward direction without first disengaging latch 210 from pin 202.
A similar arrangement is provided on stub 106 and post 120. Thus,
when windshields are loaded onto pallet 100, any torque generated
by the load will not cause post 114 or post 120 to rise within
stubs 104 or 106 respectively. The posts and stubs are thus
maintained in a fixed relationship until the latch and pin
mechanism is disengaged. Of course, the latch may alternatively be
mounted on the stubs. In this configuration, it may be desired to
use a biasing means such as a spring to maintain the latch in a
generally upright (engaged) position.
[0067] Referring now to FIG. 4A, an inside plan view of side frame
112 is shown. For purposes of discussion, side frame 112 is shown
disassembled from stub 104 and stub 110, From this view, slots 400,
402, 404, 406 and 408 of post 114 are visible. Also shown are slots
410, 412, 414, 416 and 418 of post 116. Member 420 and member 422
connect post 114 and post 116. FIG. 4B shows a plan view of post
114 looking from the rear of pallet 100.
[0068] FIG. 5A and FIG. 5B show views of front support bar 126.
Referring to FIG. 5A, which is a bottom plan view of front support
bar 126, front stop 128 and pins 500 and 502 are shown. Shown on
FIG. 5B, which is a rear plan view of front support bar 126, pins
504 and 506 are shown. Pins 500, 502, 504 and 506, in conjunction
with slots 400, 402, 404, 406 and 408, and similar slots on post
120, allow front support bar 126 to be positioned as a cross bar
between post 120 and post 114 at a plurality of heights. For
example, if it is desired to locate front support bar at a high
position, pin 504 may be inserted into slot 400, and pin 500 may be
inserted into slot 402. If a lower position is desired, pin 504 may
be inserted into slot 404, and pin 500 may be inserted into slot
406. The insertion of two pins in each post provides for added
stability.
[0069] Front support bar 126 is used when pallet 100 is fully
loaded with windshields. The height is selected such that when
pallet 100 is loaded and front support bar 126 is installed, front
stop 128 is abutted against the convex side of the foremost
windshield.
[0070] FIG. 6A and FIG. 6B show views of rear support bar 124. In
this embodiment, rear support bar 124 comprises pins 602, 604, 606
and 608 which, in conjunction with slots 410, 412, 414, 416 and
418, and similar slots on post 122, allow rear support bar 124 to
be positioned as a cross bar between post 122 and post 116 at a
plurality of heights.
[0071] Rear support bar 124 further comprises stops 610, 612, 614
and 616. Stops 610, 612, 614 and 616 are rotatably mounted to rear
support bar 124 at hinge 618 and 620. FIG. 6A shows stop 610
rotated over the top of rear support bar 124. According to one
embodiment, a detent pin is used to maintain a stop in position
over the top of rear support bar 124.
[0072] Each of stops 610, 612, 614 and 616 have a different radius
as measured from where they are connected to hinges 618 and 620 to
the point of stops 610, 612, 614 and 616 farthest from hinges 618
and 620. Thus, when rotated above rear support bar 124, each of
stops 610, 612, 614 and 616 protrude into pallet 100 to different
extents.
[0073] The stop to be used is determined based upon the curvature
of the windshield. The purpose of the rear stops is to maintain the
ears of the windshield within the box defined by the upright rigid
members of pallet 100. However, as the radius of the stop used
increases, fewer windshields may be loaded on pallet 100 since the
rearmost windshield is pushed farther forward by stops of greater
radius. Thus, it is normally desired to use the stop with the
smallest radius that still maintains the ears of the windshields
within the box defined by the upright rigid members of pallet 100.
Accordingly, stop 610, which has the smallest radius, is used with
relatively straight windshields. As the curvature of the
windshields to be loaded increases, stops of greater radius are
used to ensure the ears of the windshields are still maintained
within the box defined by the upright rigid members of pallet 100.
Rear support bar 124 and stops 610, 612, 614 and 616 thus provide
means for adapting pallet 100 to secure a variety of windshields
based upon windshields to be shipped when the windshields are of
varying shapes and sizes.
[0074] Continuing with FIGS. 6A and 6B, resilient pad 622 is
attached to stop 610. In this embodiment, a single resilient pad is
removably connectable to the stops. Alternatively, each stop may be
provided with a resilient pad. Rear support bar 124, in this
embodiment, further comprises telescoping member 624. Telescoping
member 624 comprises a plurality of holes 626. Detent pin 628
protrudes through a hole in strap 630 into one of the plurality of
hole 626 to maintain telescoping member 624 at a desired height.
The upper section of telescoping member 624 includes rounded
channel area 632 which is bounded by fins 634 and 636. Fins 634 and
636 are used to maintain a strap (not shown) on rounded channel
area 632 when telescoping member 624 is used with a partial pallet
as is explained in more detail below.
[0075] Those of skill in the art will appreciate that a number of
alternative embodiments are within the scope of the reusable
windshield pallet. By way of example, but not of limitation, more
or fewer stops may be provided. Additionally, while the embodiment
of FIGS. 6A and 6B comprises a single resilient pad which is used
interchangeably with any of stops 610, 612, 614 or 616, it may be
desired to provide resilient pads dedicated to a single stop or a
group of stops. Moreover, the pad and/or mounting area of the stop
may be curved to provide additional contact area between the
selected stop and the rearmost windshield. Additionally, the stops
may be connected to a fixed bar, and/or a horizontal member. These
alternatives and others being within the scope of the present
invention.
[0076] Referring now to FIGS. 7A, 7B, and 7C, additional detail of
longitudinal member 130 is shown. Longitudinal member 130 comprises
channel 702, hole 704 and tab 706. With reference to FIG. 7B,
insert 710 comprises protuberance 712, protuberance 714,
protuberance 720 (see FIG. 7C) and an additional protuberance (not
shown) on the fourth side of insert 710. Protuberance 712 and
protuberance 714 comprise front side 716 and 718 respectively. As
shown in FIG. 7C, insert 710 fits within channel 702. In FIG. 7C,
insert 710 has been rotated ninety degrees from the position of
insert 710 in FIG. 7B. Thus, protuberance 714 is on the bottom of
insert 710 as channel 702 is sized to receive protuberance 714, as
well as protuberance 712 and 720. Insert 710 is maintained in
position within channel 702 by a cotter pin which is inserted
through the hole in tab 706 and through a tab (not shown) provided
on the end of insert 710 which protrudes through hole 704 of
longitudinal member 130 when insert 710 is inserted into channel
702.
[0077] Each protuberance rises above the plane of longitudinal
member 130 when placed in an upright position. Thus, the concave
side of a windshield loaded into pallet 100 will abut the front
side of the protuberance rising above the plane of longitudinal
member 130. Because the protuberances each have a front side rising
out of insert 710 at a different distance from the end of insert
710, and because insert 710 may be rotated and placed within
channel 702 such that any protuberance is in the upright position,
it is possible to control the rearmost location of the bottom of a
windshield loaded into pallet 100. Insert 710 thus serves as a
means for adapting pallet 100 to secure a variety of windshields
based upon windshields to be shipped when the windshields are of
varying shapes and sizes. Thus, in this embodiment, in combination
with the selection of the rear stop as discussed above with
reference to FIGS. 6A and 6B, it is possible to maximize the
loading of the pallet, while ensuring that the ears of the loaded
windshields are maintained within the box defined by the upright
rigid members of pallet 100.
[0078] Longitudinal member 130 in this embodiment comprises a wood
base with a urethane overlay. This construction allows for reuse
while minimizing expense. Moreover, construction from these
materials has been found to reduce the amount of breakage as
compared to other materials. Those of skill in the art will
appreciate that other alternative materials may be used. Moreover,
although the embodiment of FIG. 1 comprises two lower stops, one on
each longitudinal member, more or fewer lower stops may be used.
Additionally, the inserts and protuberances may be of various
shapes, and more or fewer protuberances may be used. These
variations and others are within the scope of the reusable
windshield pallet.
[0079] Referring now to FIG. 8, an extension is shown. Extension
800 comprises lower section 802 and upper section 804. Lower
section 802 includes opening 806. Lower section 802 is connected to
upper section 804 at shoulder 808. In practice, four extensions are
provided, one for use with each upwardly rigid member of a pallet
as discussed below.
[0080] Opening 806 is sized so as to receive the upper end of post
114. However, shoulder 808 has an inside diameter that is smaller
than upper end of post 114. Accordingly, when inserted onto post
114, post 114 penetrates lower section 802 until post 114 abuts
shoulder 808. Upper section 804 is sized so as to be insertable
into flared end 206 of stub 104. Thus, when four extensions are
inserted onto four posts of a pallet, a second pallet may be placed
on top of the first pallet by inserting the flared ends of the
stubs of the second pallet onto the upper sections of the four
extensions.
[0081] By placing extensions on post 114, 116, 122 and 120, the
protective envelope of pallet 100 is extended to accommodate
windshields of greater height. Extension 800 thus provides a means
for adapting pallet 100 to secure a variety of windshields based
upon windshields to be shipped when the windshields are of a height
that would extend above posts 114, 116, 122 and 120.
[0082] Those of skill in the art will appreciate that a number of
alternative embodiments of extensions exist. By way of example, but
not of limitation, it is possible to design the posts and
extensions such that the posts are inserted into the lower section
of the extensions. Additionally, the upper section of the extension
may be solid, and/or a portion of the lower section of the
extension may be solid. Moreover, a variety of shapes may be used
in place of the generally rectangular embodiments discussed herein.
These variations and others are within the scope of the present
invention.
[0083] Referring now to FIG. 9, a side plan view of transverse
member 134 of FIG. 1 and a partial cutaway view of a side restraint
are shown. Transverse member 134 comprises ratchet notches 900.
Ratchet notches 900, in this embodiment, are located on both sides
of transverse member 134, although only one side is shown. Ratchet
notches 900 are sized to receive pawl 902 of side restraint 904.
When pawl 902 is engaged with ratchet notches 900, side restraint
904 is allowed to be moved toward the center of pallet 100 (to the
right as shown in FIG. 9), but pawl 902 does not allow movement
away from the center of pallet 100.
[0084] Pawl 902 includes hole 914 which is used to release pawl 902
from ratchet notches 900 to allow movement away from the center of
pallet 100. For example, a cable may be attached to pawl 902 at
hole 914. Pulling the cable then disengages pawl 902 from ratchet
notches 900. Pawl 902 is pivotably attached to housing 908 of side
restraint 904 at rivet 906. Side restraint 904 also includes arm
916. In this embodiment, arm 916 is constructed of a solid
material, and coated with a resilient material.
[0085] As shown in FIG. 10, housing 908 is hollow, and is sized to
hold transverse member 134. Side restraint 904 is attached to
transverse member 134 by first removing bottom plate 910. Side
restraint 904 is then placed on transverse member 134, with pawl
902 engaging ratchet notches 900 and pawl 912 engaging ratchet
notches on the side of transverse member 134 opposite the side
including ratchet notches 900. Bottom plate 910 is then reattached,
entrapping transverse member 134 within housing 908.
[0086] FIG. 11 shows details of lower front stop 142. Lower front
stop 142 comprises resilient pad 1100, stop 1102 and pivot 1104.
Lower front stop is pivotably attached to the front of frame 102,
such that when in an upright position as shown in FIG. 11,
resilient pad 1100 is facing to the rear of pallet 100.
[0087] With reference to the preceding description, loading and
unloading of a pallet constructed in accordance with the above
disclosure is now described. Of course, the descriptions of
operations are provided to aid in understanding various
embodiments, and do not limit the scope of the reusable windshield
pallet in any way. Pallet 100 begins in a stowed configuration with
side frames 112 and 118 lying on, or nearly on, frame 102.
Additionally, rear support bar 124, front support bar 126, and the
side restraints are disconnected, and preferably stored in rack
140.
[0088] Initially, side frames 112 and 118 are folded into an
upright compact position as shown in FIG. 17. As side frames 112
and 118 are brought into an upright position, the slot on each of
posts 114, 116, 118 and 120 are allowed to slide past pins,
including pin 202, located in stubs 104, 106, 108 and 110, allowing
posts 114, 116, 118 and 120 to slide into stubs 104, 106, 108 and
110. As post 114 slides into stub 104, latch 210 engages pin 202,
preventing side frame 112 from moving upwardly within stub 104 and
stub 110. A similar process occurs with respect to side frame
118.
[0089] The next series of steps may vary, depending upon the type
of pallet being loaded, full, partial, or mixed. For each type,
however, the following series of steps will place the loaded
windshields and dunnage in a compressed condition, fixing the
windshields along the longitudinal axis of the pallet.
[0090] When loading a full pallet, loading may be commenced
starting with the foremost windshield. The operator installs front
support bar 128 at the desired height, and places lower front stop
142 in the upright position. The convex side of the windshield is
placed against front stop 128 and lower front stop 142. The lower
edge of the windshield is rested on top of longitudinal members 130
and 132. Dunnage is then placed along the concave side of the
foremost windshield and the rest of the windshields are loaded with
alternating layers of dunnage. When no additional windshields can
be loaded while maintaining the ears of the rearmost windshield
within the plane defined by post 116 and post 122, the pallet is
fully loaded.
[0091] Next, the operator determines the appropriate protuberance
of insert 710 to be placed in the upright position. The appropriate
protuberance is one that will place the windshields and dunnage
into compression when insert 710 is placed into channel 702 of
longitudinal member 130. The insert for longitudinal member 132 is
similarly positioned. At this time, the operator positions rear
support bar 124 at the desired height, and rotates the desired
stop, stop 610, 612, 614 or 616, with resilient pad 622 attached
thereto, into position. This places the upper portion of the loaded
windshields and dunnage into compression. A fully loaded pallet is
shown in FIG. 16.
[0092] When loading a partial pallet, the operator begins with the
windshield that will be placed in the rearmost position. In
consideration of the curvature of the windshield, the operator
rotates the inserts in the longitudinal members, as described above
with respect to insert 710 and longitudinal member 130. Next, rear
support bar 124 is installed by placing pins 602, 604, 606 and 608
in the desired slots of posts 116 and 122. Then, the desired stop
is rotated into place and secured with a detent pin. The rearmost
windshield is then loaded into pallet 100.
[0093] At this point, the rearmost windshield should be completely
forward of the plane defined by post 116 and 122, and in a nearly
upright position. The operator then places additional windshields
on the pallet with some amount of dunnage placed between the
windshields. Next, telescoping member 624 is elevated to and
secured at the lowest position possible while maintaining the top
of rounded channel area 632 above the tallest windshield. Then, a
strap is routed from frame 102 of pallet 100 over the top of
rounded channel area 632 and over the top of the loaded
windshields. The strap is then routed over a semi-rigid member,
such as an oak plank, and protective dunnage that is placed
adjacent the foremost windshield and connected to locking bar 138
at a point near the foremost windshield. A ratchet (not shown) may
then be used to tighten the strap.
[0094] As the strap is tightened, the oak plank bends to conform to
the shape of the foremost windshield, and the windshields in the
pallet are sandwiched between the oak plank, resilient pad 622
attached to the selected stop on rear support bar 124, and the
upright protuberances of the inserts on longitudinal members 130
and 132. Typically, sufficient pressure is placed on the semi-rigid
member so that it substantially engages the foremost windshield
along the height of the windshield. It has been discovered that
white oak of about 1/2 inch thickness provides adequate flexibility
and strength to substantially conform to the windshield while
providing adequate support. Of course, other materials may be
used.
[0095] A mixed pallet is secured in much the same way as a partial
pallet. The sole difference is that the strap is attached to lower
front stop 142 for a mixed pallet rather than locking bar 138. In
both the mixed pallet and partial pallet application, telescoping
member 624 and the strap serve as a means for adapting the pallet
to secure a variety of windshields based upon the windshields to be
shipped.
[0096] Once the windshields have been secured within the forward
and rearward planes defined by the rigid upright members in
accordance with one of the foregoing methods, then the windshields
can be secured against lateral movement. This is accomplished by
installing side restraints onto transverse members 134 and 136.
With the base plate removed, side restraints are placed on
transverse members 134 and 136 as described above with reference to
FIGS. 9 and 10. The side restraints are then pushed toward the
center of pallet 100 until the arms contact the longest
windshield(s). Fixing the longest windshield in this manner
provides sufficient support to eliminate most lateral movement,
even when smaller windshields do not contact the support arms as
occurs when shipping a mixed pallet. Even if some movement occurs,
however, the arms on the side restraints will ensure that all
windshields in the pallet are maintained within the box defined by
the upright rigid members of the pallet. Thus, each side restraint
serves as a means for adapting the pallet to secure a variety of
windshields based upon the windshields to be shipped.
[0097] The final step is to verify that the top of the highest
windshield is lower than the top of side frames 112 and 118. If
needed, extensions such as the one shown in FIG. 8 may be used to
ensure the upper sides of the loaded windshields are within the box
defined by the side frames and extensions if used. In either
configuration, other pallets may be placed on top of pallet 100,
and pallet 100 may be placed on top of other loaded pallets because
the flared ends of the stubs are sized to receive the upper end of
both the extensions and the posts.
[0098] Unloading is accomplished, for the most part, by reversing
the above steps. The main difference is that the side restraints
are initially released by pulling a cable attached to hole 914 of
pawl 902. Once the windshields are unloaded, equipment removed from
the pallet, such as the support bars, extensions, strap and side
restraints, may be placed in the rack for storage. The side frames
may then be collapsed onto frame 102. In this configuration, other
pallets may be placed on top of pallet 100, and pallet 100 may be
placed on top of other pallets because the flared ends of the stubs
are sized to receive the upper end of the stubs.
[0099] Accordingly, the reusable windshield pallet provides a
device which allows for shipment of vehicle replacement glass of
non-uniform shape and/or size while minimizing breakage of the
glass in shipping. The reusable windshield pallet further provides
a device that minimizes the required amount of dunnage, and is
simple to use. Moreover, the reusable windshield pallet is of
simple, lightweight and inexpensive construction. The reusable
windshield pallet also provides a device that is stackable even
when empty and collapsed. For example, FIG. 18 illustrates three
pallets stacked on top of one another. This compact configuration
allows pallets to be shipped back for refilling in a much smaller
space. The reusable windshield pallet is versatile enough to ship
tall windshields without wasting weight and volume when shipping
short windshields. The reusable windshield pallet further provides
stops which use a minimum number of parts and which can be quickly
and easily changed to the proper distance of protrusion into the
pallet. Moreover, the present invention provides a collapsible
pallet that will not lean when stacked. Additionally, the reusable
windshield pallet provides a restraint which is quickly and easily
repositioned to the lateral position dictated by the longest
windshield in the pallet being shipped.
[0100] Referring to FIGS. 19 to 22, there is shown an embodiment of
the present invention comprising a steel frame pallet 1100. The
front of the pallet 100 is indicated by the letter F. The rear of
the pallet 100 is indicated by the letter R. The frame comprises
frame lengths 1101, 1103, 1105 and 1107 arranged in a substantially
rectangular configuration and connecting with corner stubs 1104,
1106, 1108, 1110. The forward frame length 1105 and the rear frame
length 1101 are extendible and contractible in effective length by
means of end lengths 1101a,1105a which are received in the main
tubular frame length 1101,1105 telescopically. Quick release
locking pins 1111 are provided to cooperate with aligning holes in
the frame lengths to secure the frame lengths at the appropriate
selected length. This is shown most clearly in FIG. 24, This
configuration enables the overall length of the container pallet to
be altered dependent upon specific requirements.
[0101] The corner stubs 1104, 1106, 1108, 1110 are provided with
sockets 1120 for receiving either the end lengths 1101a,1105a or
the ends of the side frame lengths 1103,1107. Side frame 1112
comprises post 1114 and post 1116. Post 1114 and post 1116 are
engaged in upward facing sockets 1130 of the respective stubs 1104
and 1110. Side frame 1118 comprises posts 1120 and 1122. Posts 1120
and 1122 are similarly engaged in the sockets 1130 of respective
stubs 1106 and 1108. A rear upper frame length extends to connect
posts 1116 and 1122 as will be described in detail later.
[0102] The frame further comprises transverse bracing steel members
1130,1132 extending transversely at the base of the structure
welded to and connecting the forward and rear frame lengths
1105,1101. A support plate 1140 is also provided, extending
transversely at the base of the structure welded to and connecting
the forward and rear frame lengths 1105,1101. Furthermore, a pair
of slider bars 1145, 1155 are welded to and connect the forward and
rear frame lengths 1105,1101 extending transversely across the
base. These have respective upper surfaces raised above the level
of the plate 1140 and bracing members 1130,1132. In use, the
windshields loaded onto the pallet container 1100 rest with their
lower edges supported on the slider bars 1145,1155. The slider
bars, as the name suggests, facilitate sliding of the windshields
into or out of the loaded position.
[0103] The forward and rear frame lengths 1105,1101 are provided
with aligned brackets 1165,1175 to receive the tines of a
respective fork-lift truck. Both opposing side frame members
1103,1107 are also provided with brackets 1185,1195 for receiving
the tines of a respective fork-lift truck. The pallet can therefore
be lifted by a fork-lift truck approaching or positioned at any
side of the container pallet.
[0104] In addition to being adjustable in length, the pallet
container is also adjustable in height. The upright posts
1114,1116,1122 and 1120 of the side frames 1112,1118 comprise inner
frame tubes received telescopically internally of the outer posts
1114,1116,1122,1120. In the configuration shown in FIGS. 19 to 22,
the container is shown in its `least height` configuration in which
the inner frame tubes are completely retracted into the outer posts
1114,1116,1122,1120. The inner tubes are inserted into the open
upper ends of the corner posts 1114,1116,1122,1120, and connected
to end bosses 1180. The side frame 1118 is provided with an upper
side frame member 1211 welded at opposing ends to the bosses 1180
of the inner tube members inserted into posts 1120,1122. The side
frame 1112 is provided with an upper side frame member 1219 welded
at opposing ends to the bosses 1180 of the inner tube members
inserted into posts 1116,1114. In order to increase the height of
the pallet container 1100, the respective upper side frame member
1211,1219 is raised such that the respective inner tube member is
simultaneously drawn out of the respective post
1114,1116,1122,1120. The telescopically extended inner tube frame
members are then secured relative to the respective post
1114,1116,1122,1120 by means of a locking pin 1127 passing through
co-aligned holes in the inner tube frame members and the posts
1114,1116,1122,1120.
[0105] In addition to being adjustable in length and height, the
pallet container is also configured to be stackable, and more than
this, stackable in different length and height configurations. In
order to achieve this receiving sockets 1182 are secured to the
bosses 1180 shaped and configured to snugly receive foot stops 1184
provided on the underside of the corner stubs 1104,1106,1108,1110,
when one container is stacked on top of another.
[0106] The pallet container is, in addition to the end frames
1112,1118, also provided with a rear frame 1290 comprising a pair
of posts 1270,1280 within which are telescopically received frame
struts 1271,1281 welded connected to a tubular frame cross member
1300. The cross member 1300 is thus height adjustable with the rest
of the pallet container 1100 as the frame struts 1271,1281 move
telescopically in the posts 1270,1280. The effective length of the
cross member 1300 is also adjustable as inner frame tubes 1310,1320
are telescopically received in the opposing ends of the cross
member 1300. The inner frame tube 1320 is shown in detail in FIGS.
28A and 28B. The upper surface of the inner frame tubes 1310,1320
is provided with a series of spaced apertures 1321 which are
arranged to line up with one of respective locking apertures
provided at opposing ends of the cross member 1300 to be secured
with a respective locking pin 1315. This fixes the cross member
1300 effective length to the required extent. As shown most clearly
in FIG. 28B, the end of the inner frame tubes 1310,1320 are
provided with a downwardly extending securing pin 1317. The
securing pin 1317 locates in an aperture 1430 provided in a
receiving seat 1420 welded to the bosses 1180 of the inner tube
members inserted into posts 1116 and 1122. The receiving seat 1420
welded to the bosses 1180 of the inner tube members is shown in
detail in FIGS. 27a-27c.
[0107] The posts 1270,1280 of the rear frame 1290 are pivotally
mounted at their lower ends to the frame member 1101. Pivotal
mounting brackets 1450 are provided for this purpose. In use, the
rear frame member is held in the upright position at the desired
height and length extension, by means of engagement of the securing
pins 1317 in the apertures 1430, with the ends of the inner frame
tubes 1310,1320 seated in the seats 1420. This is the configuration
shown in FIGS. 19, 20, 22, 24, and 25. In order to stow the pallet
container 1100 when empty (for example for storage or
transportation when not loaded with windshields), the rear frame
can be pivoted to a stowed orientation in which the posts 1270,1280
are pivoted about the pivot mounting brackets 1450 through ninety
degrees such that the posts 1270,1280 lie flat across the base of
the container pallet 1100 between the rear and front frame lengths
1101,1105. In order to do this the securing pins 1317 are lifted
out of engagement of the apertures 1430, as the ends of the inner
frame tubes 1310,1320 are lifted from being seated in the seats
1420. The cross member 1300 is then lowered such that the struts
1271,1281 move telescopically to be received completely back into
the posts 1270,1280. The rear frame can then be pivoted to the
lowered/collapsed position such that the cross member 1300 lies
contiguous against the forward frame length 1105.
[0108] The opposing side frames 1112 and 1118 are also pivotally
mounted to be collapsible from their upright orientation to lie
flat adjacent the base of the pallet container. This is achieved in
a similar manner to the arrangement described in U.S. Pat. No.
7,270,236. The lower ends of posts 1114,1116,1120,1122 are received
in the stubs 1104,1110,1108,1106. The operation will be described
in respect of the post 1120 received in the stub 1106 and shown
most clearly in FIG. 21. The other posts of the end frames are
received and operate in the same manner. The post 1120 in the
upright orientation is seated to rest in the post such that a lug
1510 is seated in a recess 1520 formed on the upper edge of the
stub 1106. The lower end of the post 1120 extends down below the
lip 1530 defined at the bottom of an open channel 1540 defined in
the stub 1106. The lower end of the post 1120 is provided with a
respective longitudinal slot 1550 provided in opposing sides, a
pivot bolt 1560 extends through the stub from one side to the other
passing through the slots 1550 in the opposing sides of the post
1120.
[0109] In order to pivot the post 1120 from its upright
orientation, the post is first lifted upwardly such that the lug
1510 is lifted out of the recess 1520 and the bottom of the post is
clear of the lip 1530. The post is then pivoted about the pivot
bolt 1560 in the direction of arrow A in FIG. 21, in order to
extend through the open channel 1540 in the stub 1106. The
respective side frames 1112,1118 pivot to collapse flat against the
already collapsed rear frame 1290. In the collapsed configuration
the collapsed pallet containers can be sacked one on top of
another. This is shown in FIG. 26, in which two collapsed pallets
are shown one stacked on top of the other. The feet 1164 of the
upper pallet container engage in the seats formed by the upper open
ends of the stubs 1104,1106,1108,1110 of the lower pallet
container.
[0110] Therefore, in addition to being adjustable in length and
height, and stackable in its upright configuration, the pallet
container is also collapsible from its `in use` condition, to a
collapsed condition in which collapsed containers can also be
stacked one on top of another.
[0111] The posts 1270,1280 of the rear frame 1290 are provided with
respective rests 1620 which are mounted to the posts 1270,1280. The
purpose of the rests 1620 is to support the windshield array when
secured in the container. In the embodiment shown the rests 1620
are movable by rotating about the axis of the posts 1270,1280
between an `in use` position shown in FIG. 22 (projecting into the
container) and a stowed position swung to a position permitting
collapsing and stacking. As a less preferred alternative the rests
1620 could be removable from the posts 1270,1280.
[0112] In the embodiment shown in the drawings, the front of the
container is open and there is no front restraint. In such an
embodiment the windshield array contained in the container is
secured by means of a straps or tethers secured to the rear frame
1290 at the cross member 1300, passing over the windshield array
and secured to the bottom front frame length 1105.
[0113] Side restraints can be provided to prevent the windshields
from shifting in the longitudinal direction of the container during
transit. In U.S. Pat. No. 7,270,236 this is achieved by means of
pivoting bar side restraints. Conveniently and beneficially
according to preferred aspects of the present invention, and as
shown in FIG. 24, the side restraints comprise flexible fluid
containing devices such as inflatable air bags 1700. The bags can
be secured to the frame by means of attachment to straps 1620. The
bags can be inflated prior to being forced into position to pack
the windshield array 1800. Alternatively the bags can be inflated
subsequently to being positioned adjacent the windshield array
1800. By using side restraints comprising flexible fluid containing
devices such as inflatable air bags 1700, the extra weight and bulk
associated side restraints such as the pivoting bar side restraints
of U.S. Pat. No. 7,270,236 can be avoided. This can reduce shipping
and storage costs. Configuring the pallet containers for use is
also less time consuming as a result of using side restraints
comprising flexible fluid containing devices such as inflatable air
bags 1700.
[0114] As shown in FIG. 24, the pallet container 1100 is extremely
versatile in that it can be expanded lengthwise from a minimum
length to extended lengths W,X,Y, and also in terms of its height
from a minimum height to extended heights E,F,G. The pallet
container can also be collapsed to an extremely compact
configuration in which the back frame 1290 remains integrally
connected in the collapsed configuration such that collapsing and
erection of the unit is conveniently achieved.
[0115] Referring now to FIGS. 29-32, there is shown an alternative
embodiment of a pallet container which is generally similar in
construction to the pallet container embodiments described above,
but in which adaptations have been made to facilitate ease of
loading in certain situations.
[0116] The embodiments of the pallet container described above are
primarily designed to be loaded from the front open side F. In
certain situations it may be desirable to load from one of the
opposed side ends of the container. Accordingly, the embodiment of
FIGS. 29-32 is designed to achieve this effect by making the upper
side frame member 1211 of the side frame 1118 effectively
detachable or displaceable in order to permit access though the
side frame 1118.
[0117] The upper side frame member 1211 is attached at one end to
the upright post 1120 by means of a hinge structure 1150. The other
end of the upper side frame member 1211 is provided with a location
pin 1160 provided on the underside of the upper side frame member
1211. The locator pin is positioned in a locating aperture provided
in the base of a locator bracket 1170. The locator bracket has U
shaped sidewalls extending upwardly from the base to provide a
secure location seat for the end of the upper side frame member
1211. In order to displace the upper side frame member 1211 from
its bracing position, the upper side frame member 1211 is pivoted
upwardly on the hinge structure 1150 enabling the opposed end to be
lifted clear of the locator bracket 1170. The upper side frame
member 1211 is then lowered pivotally about the hinge to rest in
the position shown in FIG. 30. There is sufficient play in the
hinge structure 1150 to ensure that the free end of the upper side
frame member 1211 can be displaced sideways to clear the locator
bracket as the upper side frame member 1211 is lowered. In the
displaced or lowered position (as shown in FIG. 30) the upper side
frame member 1211 may be secured to the upright 1120. For example
the locator pin may engage in a securing formation provided on the
upright post 1120.
[0118] The embodiment of FIGS. 29-32 includes a further
modification when compared to the embodiments described previously.
In this embodiment, poles 2180 can be positioned in an upright
orientation in the interior of the pallet container. The poles
enable the interior of the pallet container to be divided up into
sections and windshields positioned in the different sections
supported and divided by the poles 2180. The poles 2180 are push
fit inserted into respective ones of a series of spaced receiving
sockets 2185 positioned along respective tracks 1187 which extend
at the base of the pallet container from the front frame length
1105 toward the rear of the container, and spaced outwardly of a
respective slider bar 1145,1155.
[0119] The location of the ends of the poles 2180 in the location
sockets 2185 is sufficient to ensure that the poles are secured
with sufficient robustness, however when the pallet container has
been loaded it is possible to remove the poles 2180 from the
receiving sockets by simply pulling upwardly to free the ends from
the receiving sockets 2185. The poles 2180 locating in the sockets
2185 effectively provide a temporary or removable dividing
structure for dividing up the interior of the pallet into loading
zones.
[0120] While the present invention has been described in detail
with reference to certain exemplary embodiments thereof, such are
offered by way of non-limiting example of the invention, as other
versions are possible. Moreover, a number of design choices exist
within the scope of the present invention, some of which have been
discussed above. It is anticipated that a variety of other
modifications and changes will be apparent to those having ordinary
skill in the art and that such modifications and changes are
intended to be encompassed within the spirit and scope of the
invention as defined by the following claims.
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