U.S. patent application number 16/464983 was filed with the patent office on 2019-10-24 for crate assemblies for transporting spools of glass.
The applicant listed for this patent is CORNING INCORPORATED. Invention is credited to Donald Orrin Bigelow, Douglas Edward Brackley, Gautam Narendra Kudva, Eric Lee Miller.
Application Number | 20190322436 16/464983 |
Document ID | / |
Family ID | 60766153 |
Filed Date | 2019-10-24 |
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United States Patent
Application |
20190322436 |
Kind Code |
A1 |
Bigelow; Donald Orrin ; et
al. |
October 24, 2019 |
CRATE ASSEMBLIES FOR TRANSPORTING SPOOLS OF GLASS
Abstract
A crate assembly includes an external crate assembly (12) having
a top (16), a bottom (18), sides (20, 21) and ends (22, 23). An
internal spool support assembly (14) is located within the external
crate assembly (12). The internal spool support assembly (14)
includes a lower spool support structure (54). The lower spool
support structure (54) includes a first lower spool support
assembly (58) located at one of the ends (22, 23) of the external
crate assembly (12). A second lower spool support assembly (60) is
located at an opposite one of the ends (22, 23) of the external
crate assembly (12). The first lower spool support assembly (58) is
separated from the second lower spool support assembly (60) such
that the first and second lower spool assemblies (58, 60) may move
relative to each other.
Inventors: |
Bigelow; Donald Orrin;
(Eaton, NY) ; Brackley; Douglas Edward;
(Horseheads, NY) ; Kudva; Gautam Narendra;
(Horseheads, NY) ; Miller; Eric Lee; (Corning,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CORNING INCORPORATED |
CORNING |
NY |
US |
|
|
Family ID: |
60766153 |
Appl. No.: |
16/464983 |
Filed: |
November 29, 2017 |
PCT Filed: |
November 29, 2017 |
PCT NO: |
PCT/US2017/063578 |
371 Date: |
May 29, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62427404 |
Nov 29, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 2581/055 20130101;
B65D 85/672 20130101; B65D 81/107 20130101 |
International
Class: |
B65D 81/107 20060101
B65D081/107; B65D 85/672 20060101 B65D085/672 |
Claims
1. A crate assembly comprising: an external crate assembly
comprising a top, a bottom, sides and ends, the sides and ends
extending between the top and the bottom; an internal spool support
assembly located within the external crate assembly, the internal
spool support assembly comprising a lower spool support structure
comprising: a first lower spool support assembly located at one of
the ends of the external crate assembly, the first lower spool
support assembly comprising a spool-core receiving notch extending
therethrough and sized to receive a spool core end; and a second
lower spool support assembly located at an opposite one of the ends
of the external crate assembly, the second lower spool support
assembly comprising a spool core receiving notch extending
therethrough and sized to receive an opposite spool core end such
that the spool core is arranged substantially perpendicular to the
ends; wherein the first lower spool support assembly is separated
from the bottom of the external crate assembly by an isolation pad
positioned between the first lower spool support assembly and the
bottom of the external crate assembly and the second lower spool
support assembly is separated from the bottom of the external crate
assembly by an isolation pad positioned between the second lower
spool support assembly and the bottom of the external crate
assembly the first lower spool support assembly being separated
from the second lower spool support assembly such that the first
and second spool support assemblies are movable relative to one
other.
2. The crate assembly of claim 1, wherein the first lower spool
support assembly is separated from the sides of the external crate
assembly using isolation pads located between the first lower spool
support assembly and the sides.
3. The crate assembly of claim 2, wherein the second lower spool
support assembly is separated from the sides of the external crate
assembly using isolation pads located between the second lower
spool support assembly and the sides.
4. The crate assembly of claim 1, wherein the first lower spool
support assembly is separated from the one of the ends using an
isolation pad located between the first lower spool support
assembly and the one of the ends.
5. The crate assembly of claim 4, wherein the first lower spool
support assembly is separated from the one of the ends using
multiple, vertically oriented isolation pads that are spaced-apart
from one another in a lateral direction.
6. The crate assembly of claim 4, wherein the second lower spool
support assembly is separated from the opposite one of the ends
using an isolation pad located between the second spool support
assembly and the opposite one of the ends.
7. The crate assembly of claim 6, wherein the second lower spool
support assembly is separated from the opposite one of the ends
using multiple, vertically oriented isolation pads that are
spaced-apart from one another in a lateral direction.
8. The crate assembly of claim 1, further comprising an upper spool
support assembly comprising: a first upper spool support assembly
located at the one of the ends of the external crate assembly; and
a second upper spool support assembly located at the opposite one
of the ends of the external crate assembly; wherein the first upper
spool support assembly is separated from the top of the external
crate assembly by an isolation pad positioned between the first
upper spool support assembly and the top of the external crate
assembly and the second upper spool support assembly is separated
from the top of the external crate assembly by an isolation pad
positioned between the second upper spool support assembly and the
top of the external crate assembly.
9-12. (canceled)
13. The crate assembly of claim 1, wherein the isolation pads
comprise polyethylene foam.
14. The crate assembly of claim 1, further comprising a spool of
ultra-thin glass weighing 227 kg weight (500 pounds) or more
located therein, the spool of ultra-thin glass comprising a spool
core comprising a first core end received within the spool-core
receiving notch of the first lower spool support assembly and an
opposite second core end received within the spool-core receiving
notch of the second lower spool support assembly, the isolation pad
positioned between the first lower spool support assembly and the
bottom maintaining separation between the first lower spool support
assembly and the bottom with the first core end received within the
spool-core receiving notch of the first lower spool support
assembly.
15. A method of shipping a spool of ultra-thin glass, the method
comprising: placing a core into a crate assembly, the core
comprising a first core end, a second core end, and ultra-thin
glass rolled thereon, the crate assembly comprising: an external
crate assembly comprising a top, a bottom, sides and ends, the
sides and ends extending between the top and the bottom; an
internal spool support assembly located within the external crate
assembly, the internal spool support assembly comprising a lower
spool support structure comprising: a first lower spool support
assembly located at one of the ends of the external crate assembly,
the first lower spool support assembly comprising a spool-core
receiving notch extending therethrough and sized to receive a spool
core end; and a second lower spool support assembly located at an
opposite one of the ends of the external crate assembly, the second
lower spool support assembly comprising a spool-core receiving
notch extending therethrough and sized to receive an opposite spool
core end such that the spool core is arranged substantially
perpendicular to the ends; wherein the first lower spool support
assembly is separated from the bottom of the external crate
assembly by an isolation pad positioned between the first lower
spool support assembly and the bottom of the external crate
assembly and the second lower spool support assembly is separated
from the bottom of the external crate assembly by an isolation pad
positioned between the second lower spool support assembly and the
bottom of the external crate assembly, the first lower spool
support assembly being separated from the second lower spool
support assembly such that the first and second spool assemblies
are movable relative to each other; locating the first core end of
the spool core within the spool-core receiving notch of the first
lower spool support assembly; and locating the second core end of
the spool core within the spool-core receiving notch of the second
lower spool support assembly.
16-21. (canceled)
22. The method of claim 15, further comprising an upper spool
support assembly comprising: a first upper spool support assembly
located at the one of the ends of the external crate assembly; and
a second upper spool support assembly located at the opposite one
of the ends of the external crate assembly; wherein the first upper
spool support assembly is separated from the top of the external
crate assembly by an isolation pad positioned between the first
upper spool support assembly and the top of the external crate
assembly and the second upper spool support assembly is separated
from the top of the external crate assembly by an isolation pad
positioned between the second upper spool support assembly and the
top of the external crate assembly.
23. The method of claim 15, wherein the isolation pads comprise
polyethylene foam.
24. The method of claim 15, wherein the spool of ultra-thin glass
weighs 227 kg weight (500 pounds) or more, the isolation pad
positioned between the first lower spool support assembly and the
bottom separating the first lower spool support assembly and the
bottom with the first core end received within the spool-core
receiving notch of the first lower spool support assembly.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35
U.S.C. .sctn. 119 of U.S. Provisional Application Ser. No.
62/427,404 filed on Nov. 29, 2016, the content of which is relied
upon and incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present specification generally relates to crate
assemblies for use in transporting spools of ultra-thin glass and
to methods of transporting spools of ultra-thin glass using the
bulk spool crate assemblies.
BACKGROUND
[0003] Current shipping crates used to ship bulk flexible glass
wound on a spool may not adequately protect glass spools from
damage and the resulting lower utilization of produced glass. Glass
spools may be subjected to unintended levels of acceleration and
vibration during shipping that can result in damage to the glass
and cause increased cost to the manufacturer or customer. For
example, relatively high levels of acceleration or vibration may
occur during an impact to the shipping crates such as when crates
are dropped or mishandled e.g., with a forklift.
[0004] Accordingly, a need exists for crate assemblies and methods
of transporting spools of ultra-thin glass that can reduce
acceleration and vibration experienced by the glass product due to
an impact, which can reduce a likelihood of damage to the
glass.
SUMMARY
[0005] According to a first embodiment, a crate assembly
comprises:
[0006] an external crate assembly having a top, a bottom, sides and
ends, the sides and ends extending between the top and the
bottom;
[0007] an internal spool support assembly located within the
external crate assembly, the internal spool support assembly
comprising a lower spool support structure comprising: [0008] a
first lower spool support assembly located at one of the ends of
the external crate assembly, the first lower spool support assembly
having a spool-core receiving notch extending therethrough and
sized to receive a spool core end; and [0009] a second lower spool
support assembly located at an opposite one of the ends of the
external crate assembly, the second lower spool support assembly
having a spool-core receiving notch extending therethrough and
sized to receive an opposite spool core end such that the spool
core is arranged substantially perpendicular to the ends;
[0010] wherein the first lower spool support assembly is separated
from the bottom of the external crate assembly by an isolation pad
positioned between the first lower spool support assembly and the
bottom of the external crate assembly and the second lower spool
support assembly is separated from the bottom of the external crate
assembly by an isolation pad positioned between the second lower
spool support assembly and the bottom of the external crate
assembly, and the first lower spool support assembly is separated
from the second lower spool support assembly such that the first
and second spool support assemblies are movable relative to each
other.
[0011] According to a second embodiment, there is provided the
crate assembly of embodiment 1, wherein the first lower spool
support assembly is separated from the sides of the external crate
assembly using isolation pads located between the first lower spool
support assembly and the sides.
[0012] According to a third embodiment, there is provided the crate
assembly of embodiment 1 or embodiment 2, wherein the second lower
spool support assembly is separated from the sides of the external
crate assembly using isolation pads located between the second
lower spool support assembly and the sides.
[0013] According to a fourth embodiment, there is provided the
crate assembly of any one of embodiments 1-3, wherein the first
lower spool support assembly is separated from the one of the ends
using an isolation pad located between the first lower spool
support assembly and the one of the ends.
[0014] According to a fifth embodiment, there is provided the crate
assembly of embodiment 4, wherein the first lower spool support
assembly is separated from the one of the ends using multiple,
vertically oriented isolation pads that are spaced-apart from one
another in a lateral direction.
[0015] According to a sixth embodiment, there is provided the crate
assembly of embodiment 4 or embodiment 5, wherein the second lower
spool support assembly is separated from the opposite one of the
ends using an isolation pad located between the second spool
support assembly and the opposite one of the ends.
[0016] According to a seventh embodiment, there is provided the
crate assembly of embodiment 6, wherein the second lower spool
support assembly is separated from the opposite one of the ends
using multiple, vertically oriented isolation pads that are
spaced-apart from one another in a lateral direction.
[0017] According to an eighth embodiment, there is provided the
crate assembly of any one of embodiments 1-7, further comprising an
upper spool support assembly comprising:
[0018] a first upper spool support assembly located at the one of
the ends of the external crate assembly; and
[0019] a second upper spool support assembly located at the
opposite one of the ends of the external crate assembly;
[0020] wherein the first upper spool support assembly is separated
from the top of the external crate assembly by an isolation pad
positioned between the first upper spool support assembly and the
top of the external crate assembly and the second upper spool
support assembly is separated from the top of the external crate
assembly by an isolation pad positioned between the second upper
spool support assembly and the top of the external crate
assembly.
[0021] According to a ninth embodiment, there is provided the crate
assembly of embodiment 8, wherein the first upper spool support
assembly is separated from the one of the ends an isolation pad
located between the first lower spool support assembly and the one
of the ends.
[0022] According to a tenth embodiment, there is provided the crate
assembly of embodiment 9, wherein the first upper spool support
assembly is separated from the one of the ends using multiple,
vertically oriented isolation pads that are spaced-apart from one
another in a lateral direction.
[0023] According to an eleventh embodiment, there is provided the
crate assembly of embodiment 9 or embodiment 10, wherein the second
upper spool support assembly is separated from the opposite one of
the ends using an isolation pad located between the second upper
support assembly and the opposite one of the ends.
[0024] According to a twelfth embodiment, there is provided the
crate assembly of embodiment 11, wherein the second upper spool
support assembly is separated from the opposite one of the ends
using multiple, vertically oriented isolation pads that are
spaced-apart from one another in a lateral direction.
[0025] According to a thirteenth embodiment, there is provided the
crate assembly of any one of embodiments 1-12, wherein the
isolation pads comprise polyethylene foam.
[0026] According to a fourteenth embodiment, there is provided the
crate assembly of any one of embodiments 1-13, further comprising a
spool of ultra-thin glass weighing 227 kg weight (500 pounds) or
more located therein, the spool of ultra-thin glass including a
spool core having a first core end received within the spool-core
receiving notch of the first lower spool support assembly and an
opposite second core end received within the spool-core receiving
notch of the second lower spool support assembly, the isolation pad
positioned between the first lower spool support assembly and the
bottom maintaining separation between the first lower spool support
assembly and the bottom with the first core end received within the
spool-core receiving notch of the first lower spool support
assembly.
[0027] According to a fifteenth embodiment, a method of shipping a
spool of ultra-thin glass comprises:
[0028] placing a core into a crate assembly, the core comprising a
first core end, a second core end, and ultra-thin glass rolled
thereon, the crate assembly comprising: [0029] an external crate
assembly having a top, a bottom, sides and ends, the sides and ends
extending between the top and the bottom; [0030] an internal spool
support assembly located within the external crate assembly, the
internal spool support assembly comprising a lower spool support
structure comprising: [0031] a first lower spool support assembly
located at one of the ends of the external crate assembly, the
first lower spool support assembly having a spool-core receiving
notch extending therethrough and sized to receive a spool core end;
and [0032] a second lower spool support assembly located at an
opposite one of the ends of the external crate assembly, the second
lower spool support assembly having a spool-core receiving notch
extending therethrough and sized to receive an opposite spool core
end such that the spool core is arranged substantially
perpendicular to the ends; [0033] wherein the first lower spool
support assembly is separated from the bottom of the external crate
assembly by an isolation pad positioned between the first lower
spool support assembly and the bottom of the external crate
assembly and the second lower spool support assembly is separated
from the bottom of the external crate assembly by an isolation pad
positioned between the second lower spool support assembly and the
bottom of the external crate assembly, and the first lower spool
support assembly is separated from the second lower spool support
assembly such that the first and second spool assemblies are
movable relative to each other;
[0034] locating the first core end of the spool core within the
spool-core receiving notch of the first lower spool support
assembly; and
[0035] locating the second core end of the spool core within the
spool-core receiving notch of the second lower spool support
assembly.
[0036] According to a sixteenth embodiment, there is provided the
method of embodiment 15, wherein the first lower spool support
assembly is separated from the sides of the external crate assembly
using isolation pads located between the first lower spool support
assembly and the sides.
[0037] According to a seventeenth embodiment, there is provided the
method of embodiment 15 or 16, wherein the second lower spool
support assembly is separated from the sides of the external crate
assembly using isolation pads located between the second lower
spool support assembly and the sides.
[0038] According to an eighteenth embodiment, there is provided the
method of any one of embodiments 15-17, wherein the first lower
spool support assembly is separated from the one of the ends using
an isolation pad located between the first lower spool support
assembly and the one of the ends.
[0039] According to a nineteenth embodiment, there is provided the
method of embodiment 18, wherein the first lower spool support
assembly is separated from the one of the ends using multiple,
vertically oriented isolation pads that are spaced-apart from one
another in a lateral direction.
[0040] According to a twentieth embodiment, there is provided the
method of embodiment 18 or embodiment 19, wherein the second lower
spool support assembly is separated from the opposite one of the
ends using an isolation pad located between the second spool
support assembly and the opposite one of the ends.
[0041] According to a twenty-first embodiment, there is provided
the method of embodiment 20, wherein the second lower spool support
assembly is separated from the opposite one of the ends using
multiple, vertically oriented isolation pads that are spaced-apart
from one another in a lateral direction.
[0042] According to a twenty-second embodiment, there is provided
the method of any one of embodiments 15-21, further comprising an
upper spool support assembly comprising:
[0043] a first upper spool support assembly located at the one of
the ends of the external crate assembly; and
[0044] a second upper spool support assembly located at the
opposite one of the ends of the external crate assembly;
[0045] wherein the first upper spool support assembly is separated
from the top of the external crate assembly by an isolation pad
positioned between the first upper spool support assembly and the
top of the external crate assembly and the second upper spool
support assembly is separated from the top of the external crate
assembly by an isolation pad positioned between the second upper
spool support assembly and the top of the external crate
assembly.
[0046] According to a twenty-third embodiment, there is provided
the method of any one of embodiments 15-22, wherein the isolation
pads comprise polyethylene foam.
[0047] According to a twenty-fourth embodiment, there is provided
the method of any one of embodiments 15-23, wherein the spool of
ultra-thin glass weighs 227 kg weight (500 pounds) or greater, the
isolation pad positioned between the first lower spool support
assembly and the bottom separating the first lower spool support
assembly and the bottom with the first core end received within the
spool-core receiving notch of the first lower spool support
assembly.
[0048] Additional features and advantages will be set forth in the
detailed description which follows, and in part will be readily
apparent to those skilled in the art from the description or
recognized by practicing the embodiments as exemplified in the
written description and the appended drawings and as defined in the
appended claims. It is to be understood that both the foregoing
general description and the following detailed description are
merely exemplary, and are intended to provide an overview or
framework to understanding the nature and character of the
claims.
[0049] The accompanying drawings are included to provide a further
understanding of principles of the present disclosure, and are
incorporated in and constitute a part of this specification. The
drawings illustrate one or more embodiment(s), and together with
the description serve to explain, by way of example, principles and
operation of the embodiments described herein. It is to be
understood that various features disclosed in this specification
and in the drawings can be used in any and all combinations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] FIG. 1 depicts a perspective view of a bulk crate assembly
for shipping ultra-thin glass spools, according to one or more
embodiments shown and described herein;
[0051] FIG. 2 depicts a side view of the bulk crate assembly of
FIG. 1 with a top and side removed, according to one or more
embodiments shown and described herein;
[0052] FIG. 3 depicts an end view of the crate assembly of FIG. 1
with upper and lower outer wall members removed, according to one
or more embodiments shown and described herein;
[0053] FIG. 4 depicts an end view of the crate assembly of FIG. 1
with upper and lower outer wall members removed, according to one
or more embodiments shown and described herein; and
[0054] FIG. 5 depicts a section view of the bulk crate assembly of
FIG. 1 with a spool of ultra-thin glass, according to one or more
embodiments shown and described herein.
DETAILED DESCRIPTION
[0055] In the following detailed description, for purposes of
explanation and not limitation, example embodiments disclosing
specific details are set forth to provide a thorough understanding
of various principles of the present disclosure. However, it will
be apparent to one having ordinary skill in the art, having had the
benefit of the present disclosure, that the present disclosure may
be practiced in other embodiments that depart from the specific
details disclosed herein. Moreover, descriptions of well-known
devices, methods and materials may be omitted so as not to obscure
the description of various principles of the present disclosure.
Finally, wherever applicable, like reference numerals refer to like
elements.
[0056] As used herein, the term "about" means that amounts, sizes,
formulations, parameters, and other quantities and characteristics
are not and need not be exact, but may be approximate and/or larger
or smaller, as desired, reflecting tolerances, conversion factors,
rounding off, measurement error and the like, and other factors
known to those of skill in the art. When the term "about" is used
in describing a value or an end-point of a range, the disclosure
should be understood to include the specific value or end-point
referred to. Whether or not a numerical value or end-point of a
range in the specification recites "about," the numerical value or
end-point of a range is intended to include two embodiments: one
modified by "about," and one not modified by "about." It will be
further understood that the endpoints of each of the ranges are
significant both in relation to the other endpoint, and
independently of the other endpoint.
[0057] Directional terms as used herein--for example up, down,
right, left, front, back, top, bottom--are made only with reference
to the figures as drawn and are not intended to imply absolute
orientation.
[0058] Unless otherwise expressly stated, it is in no way intended
that any method set forth herein be construed as requiring that its
steps be performed in a specific order. Accordingly, where a method
claim does not actually recite an order to be followed by its steps
or it is not otherwise specifically stated in the claims or
descriptions that the steps are to be limited to a specific order,
it is no way intended that an order be inferred, in any respect.
This holds for any possible non-express basis for interpretation,
including: matters of logic with respect to arrangement of steps or
operational flow; plain meaning derived from grammatical
organization or punctuation; the number or type of embodiments
described in the specification.
[0059] As used herein, the singular forms "a," "an" and "the"
include plural referents unless the context clearly dictates
otherwise. Thus, for example, reference to a "component" includes
embodiments having two or more such components, unless the context
clearly indicates otherwise.
[0060] Embodiments described herein relate generally to crate
assemblies for use in transporting spools of ultra-thin glass and
to methods of transporting spools of ultra-thin glass using the
crate assemblies. The crate assemblies include an external crate
assembly that has an internal spool support assembly located
therein. The internal spool support assembly includes isolation
pads positioned between the internal spool support assembly and the
external crate assembly to facilitate damped movement of the
internal spool support assembly relative to the external crate
assembly. This damped movement of the internal spool support
assembly within the external crate assembly can allow the spool of
ultra-thin glass to float within the external crate assembly. Such
a floating arrangement for the spool of ultra-thin glass within the
external crate assembly can reduce acceleration and vibration
experienced by the spool of ultra-thin glass due to, for example,
an impact to the external crate assembly during an impact
event.
[0061] Without wishing to be bound by theory, it has been
discovered that spools of ultra-thin glass (e.g., glass of about
0.3 mm or less in thickness) within conventional shipping crates
can experience damage under accelerations of about 70 times the
acceleration due to gravity during impact testing. On the other
hand, it is believed that spools of ultra-thin glass exhibit
significantly reduced likelihood of damage under accelerations of
less than or equal to about 20 times the acceleration due to
gravity. Such reduced accelerations can be accomplished by applying
a smaller force to the spool of ultra-thin glass over a longer
period of time compared to a larger force over a shorter period of
time.
[0062] As used herein, the term "longitudinal direction" refers to
the elongated direction or lengthwise direction of the crate
assembly (i.e., in the +/-X-direction of the coordinate axes
depicted in the figures). The term "lateral direction" refers to
the cross-wise direction of the crate assembly (i.e., in the
+/-Y-direction of the coordinate axes depicted in the figures), and
is transverse to the longitudinal direction. The term "vertical
direction" refers to the upward-downward direction of the crate
assembly (i.e., in the +/-Z-direction of the coordinate axes
depicted in the figures).
[0063] Referring to FIG. 1, a crate assembly 10 includes an
external crate assembly 12 and an internal spool support assembly
14 located within the external crate assembly 12. The external
crate assembly 12 and internal spool support assembly 14 together
form an upper crate assembly 15 and a lower crate assembly 17. The
external crate assembly 12 includes a top 16, a bottom 18, and
sides 20, 21 and ends 22, 23 that extend between the top 16 and the
bottom 18. Located on the top 16 of the external crate assembly are
guide members 24. The guide members 24 include a lengthwise
extending portion 26 that extends in the longitudinal direction and
a widthwise extending portion 28 that extends in the lateral
direction across a gap 30 between the lengthwise extending portions
26 and the sides 20 and 21. The guide members 24 and resulting gaps
30 can facilitate stacking and securing crate assemblies 10, one on
top of another for bulk shipping of the crate assemblies 10, for
example, within a cargo container. Crate assemblies 10 may be
shipped in stacks from one to eight crates high.
[0064] The bottom 18 includes support members 32 upon which the
bottom 18 can rest elevated from the ground or floor. Spaces 34
between adjacent ones of the support member 32 can be sized to
allow forks of a forklift to be inserted therein for a lifting and
transport operation. The support members 32 extend lengthwise along
the bottom 18 in the longitudinal direction. Widths of the support
members 32 in the transverse direction are sized to be received by
the gaps 30 between the lengthwise extending portions 26 and the
sides 20 and 22 to facilitate stacking of the crate assemblies
10.
[0065] The external crate assembly 12 includes the ends 22 and 23.
The ends 22 and 23 each include a lower outer wall member 36
connected to the bottom 18 and an upper outer wall member 38
connected to the top 16 (only end 22 can be seen). The lower outer
wall member 36 includes a spool-core receiving notch 46 sized to
receive a spool core end. In some embodiments, the spool-core
receiving notch 46 has an open side 48 closed by a bottom ledge 50
of the upper outer wall member 38. The upper outer wall member 38
may include handles 52 (e.g., openings) that can facilitate manual
removal of the upper crate assembly 15 from the lower crate
assembly 17, e.g., to access the spool of ultra-thin glass located
therein.
[0066] Referring to FIG. 2, the crate assembly 10 is illustrated
with the top 16 and side 20 removed to show the internal spool
support assembly 14 within the volume 40. The internal spool
support assembly 14 includes a lower spool support structure 54 and
an upper spool support structure 56. The lower spool support
structure 54 includes a first lower spool support assembly 58
located at the end 22 and a second lower spool support assembly 60
located at the opposite end 23 of the external crate assembly 12.
The first and second lower spool support assemblies 58 and 60 are
spaced-apart from one another and disconnected such that they can
move relative to one another during use. The first lower spool
support assembly 58 includes vertically arranged, side-by-side
support members 62 and 64 that together form an end support
structure 65 for supporting a spool core end of a spool of
ultra-thin glass. The support members 62 and 64 are illustrated as
being substantially planar board-like structures and extend
widthwise in the lateral direction between the sides 20 and 21 of
the external crate assembly 12. It should be noted that while two
support members 62 and 64 are illustrated, there may be more or
less than two support members, depending on the size and weight of
the spool of ultra-thin glass to be transported. Each support
member 62 and 64 includes a spool-core receiving notch 69 (FIG. 1)
that aligns with the spool-core receiving notch 46 of the lower
outer wall member 36.
[0067] Similarly, the second lower spool support assembly 60
includes vertically arranged, side-by-side support members 66 and
68 that together form an end support structure 71 for supporting
the spool core end of the spool of ultra-thin glass. The support
members 66 and 68 are illustrated as being substantially planar
board-like structures and extend widthwise in the lateral direction
between the sides 20 and 21 of the external crate assembly 12. As
above, while two support members 66 and 68 are illustrated, there
may be more or less than two support members, depending on the size
and weight of the spool of ultra-thin glass to be transported. Each
support member 66 and 68 includes a spool-core receiving notch 70
that aligns with a spool-core receiving notch 72 of lower outer
wall member 75. The spool-core receiving notches 70 also align with
the spool-core receiving notches 69 so that a central axis of the
spool of the ultra-thin glass is substantially perpendicular to the
ends 22 and 23 of the external crate assembly 12 when supported by
the first and second lower spool support assemblies 58 and 60.
[0068] The first lower spool support assembly 58 is separated from
the bottom 18 using a bottom isolation pad 76. The bottom isolation
pad 76 may be a single isolation pad that extends a majority or
substantially all of a width of the support members 62 and 64. The
bottom isolation pad 76 may also extend across the entire thickness
of both support members 62 and 64 to support the support members 62
and 64 spaced-from the bottom 18. In some embodiments, multiple
bottom isolation pads may be used. The number and dimension of the
bottom isolation pad 76 may be selected depending on the size and
dimension of, for example, the spool of the ultra-thin glass.
[0069] The first lower spool support assembly 58 may further be
separated from the side 20 using side isolation pads 78 and 80. The
side isolation pads 78 and 80 may extend along only portions of the
heights of the support members 62 and 64. The side isolation pads
78 and 80 may also extend across the entire thickness of both
support members 62 and 64 to support the support members 62 and 64
spaced-from the side 20. In some embodiments, a single side
isolation pad may be used that extends along all or only some of
the height of the support members 62 and 64. The number and
dimension of the side isolation pads 78 and 80 may be selected
depending on the size and dimension of, for example, the spool of
the ultra-thin glass.
[0070] Referring to FIG. 3 illustrating the crate assembly 10 with
the lower outer wall member 36 and the upper outer wall member 38
removed, the first lower spool assembly 58 may also be separated
from the end 22 using end isolation pads 82, 84, 86 and 88. The end
isolation pads 82, 84, 86 and 88 may extend along a height of the
support members 62 and 64 and be sandwiched between the support
member 64 and the lower outer wall member 36 (FIG. 1). As can be
seen, the end isolation pads 82, 84, 86 and 88 extend vertically
along a height of the support member 64. Multiple end isolation
pads 82, 84, 86 and 88 are provided that are each spaced from one
another in the widthwise direction. While the end isolation pads
82, 84, 86 and 88 are illustrated as being elongated in the
vertical direction, they may be elongated in the widthwise
direction. For example, as an alternative to being spaced-apart in
the widthwise direction, the end isolation pads may extend
laterally and be spaced-apart in the vertical direction. The number
and dimension of the end isolation pads 82, 84, 86 and 88 may be
selected depending on the size and dimension of, for example, the
spool of the ultra-thin glass.
[0071] Referring still to FIG. 3, the first lower spool support
assembly 58 may further be separated from the side 21 using side
isolation pads 90 and 92. The side isolation pads 90 and 92 may
extend along only portions of the heights of the support members 62
and 64. The side isolation pads 90 and 92 may also extend across
the entire thickness of both support members 62 and 64 to support
the support members 62 and 64 spaced-from the side 21. In some
embodiments, a single side isolation pad may be used that extends
along all or only some of the height of the support members 62 and
64. The number and dimension of the side isolation pads 90 and 92
may be selected depending on the size and dimension of, for
example, the spool of the ultra-thin glass. As can be appreciated,
the side isolation pads 78, 80, 90 and 92 isolate the first lower
spool support assembly 58 from opposite sides 20 and 21, the end
isolation pads 82, 84, 86 and 88 isolate the first lower spool
support assembly 58 from the end 22 and the bottom isolation pad 76
isolates the first lower spool support assembly 58 from the bottom
18.
[0072] Referring again to FIG. 2, the second lower spool support
assembly 60 is separated from the bottom 18 using a bottom
isolation pad 106. The bottom isolation pad 106 may be a single
isolation pad that extends a majority or substantially all of a
width of the support members 66 and 68. The bottom isolation pad
106 may also extend across the entire thickness of both support
members 66 and 68 to support the support members 66 and 68
spaced-from the bottom 18. In some embodiments, multiple bottom
isolation pads may be used. The number and dimension of the bottom
isolation pad 106 may be selected depending on the size and
dimension of, for example, the spool of the ultra-thin glass.
[0073] The second lower spool support assembly 60 may further be
separated from the side 20 using side isolation pads 108 and 110.
The side isolation pads 108 and 110 may extend along only portions
of the heights of the support members 66 and 68. The side isolation
pads 78 and 80 may also extend across the entire thickness of both
support members 66 and 68 to support the support members 66 and 68
spaced-from the side 20. In some embodiments, a single side
isolation pad may be used that extends along all or only some of
the height of the support members 66 and 68. The number and
dimension of the side isolation pads 78 and 80 may be selected
depending on the size and dimension of, for example, the spool of
the ultra-thin glass.
[0074] Referring to FIG. 4, illustrating the crate assembly 10 with
the lower outer wall member 75 and the upper outer wall member 77
removed (FIG. 2), the second lower spool assembly 60 may also be
separated from the end 23 using end isolation pads 112, 114, 116
and 118. The end isolation pads 112, 114, 116 and 118 may extend
along a height of the support members 66 and 68 and be sandwiched
between the support member 68 and the lower outer wall member 75.
As can be seen, the end isolation pads 112, 114, 116 and 118 extend
vertically along a height of the support member 68. Multiple end
isolation pads 112, 114, 116 and 118 are provided that are each
spaced from one another in the widthwise direction. While the end
isolation pads 112, 114, 116 and 118 are illustrated as being
elongated in the vertical direction, they may be elongated in the
widthwise direction. For example, as an alternative to being
spaced-apart in the widthwise direction, the end isolation pads may
extend laterally and be spaced-apart in the vertical direction. The
number and dimension of the end isolation pads 112, 114, 116 and
118 may be selected depending on the size and dimension of, for
example, the spool of the ultra-thin glass.
[0075] Referring still to FIG. 4, the second lower spool support
assembly 60 may further be separated from the side 21 using side
isolation pads 120 and 122. The side isolation pads 120 and 122 may
extend along only portions of the heights of the support members 66
and 68. The side isolation pads 120 and 122 may also extend across
the entire thickness of both support members 66 and 68 to support
the support members 66 and 68 spaced-from the side 21. In some
embodiments, a single side isolation pad may be used that extends
along all or only some of the height of the support members 66 and
68. The number and dimension of the side isolation pads 120 and 122
may be selected depending on the size and dimension of, for
example, the spool of the ultra-thin glass. As can be appreciated,
the side isolation pads 108, 110, 120 and 122 isolate the second
lower spool support assembly 60 from opposite sides 20 and 21, the
end isolation pads 112, 114, 116 and 118 isolate the second lower
spool support assembly 60 from the end 23 and the bottom isolation
pad 106 isolates the second lower spool support assembly 60 from
the bottom 18.
[0076] Referring again to FIG. 2, the internal spool support
assembly 14 includes the upper spool support structure 56. The
upper spool support structure 56 includes a first upper spool
support assembly 126 located at the end 22 and a second upper spool
support assembly 128 located at the opposite end 23 of the external
crate assembly 12. The first and second upper spool support
assemblies 126 and 128 are spaced-apart from one another and
disconnected such that they can move relative to one another during
use. The first upper spool support assembly 126 includes vertically
arranged, side-by-side support members 130 and 132 that together
form an end support structure 134 for supporting the spool core end
of the spool of ultra-thin glass from above. The support members
130 and 132 are illustrated as being substantially planar and
extending widthwise in the lateral direction between the sides 20
and 21 of the external crate assembly 12. It should be noted that
while two support members 130 and 132 are illustrated, there may be
more or less than two support members, depending on the size and
weight of the spool of ultra-thin glass to be transported. Each
support member 130 and 132 includes a lower edge 135 that engages
the support members 62 and 64 of the first lower support assembly
58 thereby enclosing their respective spool-core receiving notches
69.
[0077] Similarly, the second upper spool support assembly 128
includes vertically arranged, side-by-side support members 136 and
138 that together form an end support structure 140 for supporting
the spool core end of the spool of ultra-thin glass. The support
members 136 and 138 are illustrated as being substantially planar
and extend widthwise in the lateral direction between the sides 20
and 21 of the external crate assembly 12. As above, while two
support members 136 and 138 are illustrated, there may be more or
less than two support members, depending on the size and weight of
the spool of ultra-thin glass to be transported. Each support
member 136 and 138 includes a lower edge 141 that engages the
support members 66 and 68 of the second lower support assembly 60
thereby enclosing their respective spool-core receiving notches
70.
[0078] The first upper spool support assembly 126 is separated from
the top 16 using a top isolation pad 142. The top isolation pad 142
may be a single isolation pad that extends a majority or
substantially all of a width of the support members 130 and 132.
The top isolation pad 142 may also extend across the entire
thickness of both support members 130 and 132 to support the
support members 130 and 132 spaced-from the top 16. In some
embodiments, multiple top isolation pads may be used. The number
and dimension of the top isolation pad 142 may be selected
depending on the size and dimension of, for example, the spool of
the ultra-thin glass.
[0079] Unlike the first lower spool support assembly 58, the first
upper spool support assembly 126 may not include side isolation
pads that separate the first upper spool support assembly 126 from
the sides 20 and 21. In this example, side isolation pads are not
necessary on the upper spool support assembly 126 because the first
upper spool support assembly 126 provides relatively little or no
lateral support for the spool of ultra-thin glass as the spool core
rests squarely within the spool-core receiving notches 69 of the
first lower spool support assembly 58. In other embodiments,
however, such as where the first upper spool support assembly 126
includes a spool-core receiving notch, side isolation pads may be
used to isolate the first upper spool support assembly 126 from the
sides 20 and 21 of the external crate assembly 12.
[0080] Referring again to FIG. 3, the first upper spool support
assembly 126 may also be separated from the end 22 using end
isolation pads 156, 158, 160 and 162. The end isolation pads 156,
158, 160 and 162 may extend along a height of the support members
130 and 132 and be sandwiched between the support member 132 and
the upper outer wall member 38 (FIG. 1). As can be seen, the end
isolation pads 156, 158, 160 and 162 extend vertically along a
height of the support member 132 and are aligned with the end
isolation pads 82, 84, 86 and 88 thereby forming columns. In other
embodiments, the end isolation pads may not be aligned. In
alternative embodiments, the end isolation pads 156, 158, 160 and
162 may be formed as one-piece with and an extension of the
corresponding end isolation pads 82, 84, 86, and 88. Multiple end
isolation pads 156, 158, 160 and 162 are provided that are each
spaced from one another in the widthwise direction. While the end
isolation pads 156, 158, 160 and 162 are illustrated as being
elongated in the vertical direction, they may be elongated in the
widthwise direction. For example, as an alternative to being
spaced-apart in the widthwise direction, the end isolation pads may
extend laterally and be spaced-apart in the vertical direction. The
number and dimension of the end isolation pads 156, 158, 160 and
162 may be selected depending on the size and dimension of, for
example, the spool of the ultra-thin glass. As can be appreciated,
the end isolation pads 156, 158, 160 and 162 isolate the first
upper spool support assembly 126 from the end 22 and the top
isolation pad 142 isolates the first upper spool support assembly
126 from the top 16.
[0081] Referring again to FIG. 2, the second upper spool support
assembly 128 is separated from the top 16 using a top isolation pad
166. The top isolation pad 166 may be a single isolation pad that
extends a majority or substantially all of a width of the support
members 136 and 138. The top isolation pad 166 may also extend
across the entire thickness of both support members 136 and 138 to
support the support members 136 and 138 spaced-from the top 16. In
some embodiments, multiple top isolation pads may be used. The
number and dimension of the top isolation pad 166 may be selected
depending on the size and dimension of, for example, the spool of
the ultra-thin glass.
[0082] Unlike the second lower spool support assembly 60, the
second upper spool support assembly 128 may not include side
isolation pads that separate the second upper spool support
assembly 128 from the sides 20 and 21. As noted above regarding the
upper spool supporting assembly 126, side isolation pads are not
necessary on upper spool supporting assembly 128 because the second
upper spool support assembly 128 provides relatively little or no
lateral support for the spool of ultra-thin glass as the spool core
rests squarely within the spool-core receiving notches 70 of the
second lower spool support assembly 60. In other embodiments,
however, such as where the second upper spool support assembly 128
includes a spool-core receiving notch, side isolation pads may be
used to isolate the second upper spool support assembly 128 from
the sides 20 and 21 of the external crate assembly 12.
[0083] Referring again to FIG. 4, the second upper spool support
assembly 128 may also be separated from the end 23 using end
isolation pads 170, 172, 174 and 176. The end isolation pads 170,
172, 174 and 176 may extend along a height of the support members
136 and 138 and be sandwiched between the support member 138 and
the upper outer wall member 77. As can be seen, the end isolation
pads 170, 172, 174 and 176 extend vertically along a height of the
support member 138 and are aligned with the end isolation pads 112,
114, 116 and 118 thereby forming columns. In other embodiments, the
end isolation pads may not be aligned. In some embodiments, the end
isolation pads 170, 172, 174 and 176 may be formed as one-piece
with and an extension of the corresponding end isolation pads 112,
114, 116 and 118. Multiple end isolation pads 170, 172, 174 and 176
are provided that are each spaced from one another in the widthwise
direction. While the end isolation pads 170, 172, 174 and 176 are
illustrated as being elongated in the vertical direction, they may
be elongated in the widthwise direction. For example, as an
alternative to being spaced-apart in the widthwise direction, the
end isolation pads may extend laterally and be spaced-apart in the
vertical direction. The number and dimension of the end isolation
pads 170, 172, 174 and 176 may be selected depending on the size
and dimension of, for example, the spool of the ultra-thin glass.
As can be appreciated, the end isolation pads 170, 172, 174 and 176
isolate the second upper spool support assembly 128 from the end 23
and the top isolation pad 166 isolates the second upper spool
support assembly 128 from the top 16.
[0084] Referring to FIG. 5, the crate assembly 10 is illustrated
including the external crate assembly 12 and the internal spool
support assembly 14. A spool 200 of ultra-thin glass is supported
by the internal spool support assembly 14. The spool 200 of
ultra-thin glass may weigh from about 181 kg (400 pounds) to about
362 kg (800 pounds), such as about 227 kg weight (500 pounds) or
more, such as about 272 kg (600 pounds). The spool 200 includes a
spool core 202 and spool flanges 204 and 206 that are located at
opposite ends 208 and 210 of the wound, ultra-thin glass 212. Spool
core ends 214 and 216 protrude outwardly beyond the spool flanges
204 and 206. The spool core end 214 is received by the spool-core
receiving notches 69 of the first lower spool support assembly 58
and spool core end 216 is received by the spool-core receiving
notches 70 of the second lower spool support assembly 60. In some
embodiments, spool flanges 204, 206, need not be present.
[0085] As can be seen, even with the weight of the spool 200
present, the bottom isolation pads 76 and 106 can maintain
separation of the first and second lower spool support assemblies
58 and 60 from the bottom 16 of the external crate assembly 12. The
isolation pads may be formed of a material of suitable density to
absorb the vibration, shock, and acceleration of the spool. In
certain embodiments, this material may be from about 0.254 cm to
about 12.7 cm (0.1 inch to 5 inches) thick. In other embodiments,
the material may be from about 0.5 cm to about 10.2 cm (0.2 inch to
4 inches) thick. In still other embodiments, this material may be
from about 0.76 cm to about 7.6 cm (0.3 inch to 3 inches) thick. In
yet further embodiments, this material may be from about 2 cm to
about 5 cm (0.8 to 2 inches) thick depending on the location of the
material in the crate. The material in certain embodiments may
comprise a polyethylene foam, such as commercially available as DOW
Ethafoam HS 900 and the like.
[0086] Tests standardized by the International Safe Transit
Association ("ISTA") Procedure 3B may be used to test the forces
acting on the crate assembly. Procedure 3B is a general simulation
test for packaged-products shipped through a motor carrier (truck)
delivery system, where different types of packaged-products, often
from different shippers and intended for different ultimate
destinations, are mixed in the same load. This type of shipment is
called LTL (less-than-truckload).
[0087] To assemble various embodiments, a manufacturer may start
with the bottom. The bottom may be a thin, substantially flat board
selected to support the external crate assembly, the upper and
lower spool support structures and the bulk spool. The bottom may
be made from wood, plastic, metal, or the like. Structure may be
added to the bottom to form slots for the insertion of a fork
lift's forks and to make the external crate assembly stackable.
These slots may make transfer and carrying of the crates via
forklift or other suitable carrier more efficient. Certain
embodiments of the crate assembly may ship in containers in which
they are stacked from one to eight crates high.
[0088] Attached to the bottom may be the remaining external crate
assembly including four substantially planar sides that may make up
the walls extending between the top and bottom pieces of the
external crate assembly. These sides may be arranged such that they
form a rectangular shaped box, each side being substantially
orthogonal to the other sides on either side of it. These sides may
be made of wood, plastic, metal, or any other suitable material.
These sides may be attached via nails, screws, bolts, brackets, or
some other suitable methods, or may be attached via an epoxy. Some
of the sides may be split into two sections, an upper and a lower,
that are removably coupled to one another, such that the top part
of the side may be permanently connected to the external assembly
top and the bottom part of the side may be permanently connected to
the bottom of the external crate assembly. The sides may contain
handles, slots, or some other suitable means to make the handling
of the walls easier and more convenient for the users of the crate
assembly. Two opposite sides may have a spool-core receiving notch
extending therethrough, this spool-core receiving notch designed
such that the notch cradles a spool core end of the spool and
inhibits movement of the spool during transport.
[0089] To assemble the isolation pads, the isolation pads may be
adhered or otherwise connected to the external crate assembly at
the various locations discussed above. The top section may be
constructed in a fashion similar to the bottom section, starting
with a substantially flat piece of wood, plastic, metal, or the
like and adding two or four sides, each substantially orthogonal to
the sides surrounding it. The sides may include pre-fabricated
handles in the form of voids, or may be external to the wall
structure in such form as a handle, rope, or the like. These
handles may be added to the walls of the top piece of the external
crate assembly after the top piece has been removably connected
with the bottom piece or before. Once the top section is
constructed, isolation pads may be placed within the top section as
described above. The upper and lower support structures may then be
assembled to their respective top and bottom sections.
[0090] The ultra-thin flexible glass may have a thickness of about
0.3 mm or less including but not limited to thicknesses of, for
example, about 0.01-0.05 mm, about 0.05-0.1 mm, about 0.1-0.15 mm,
about 0.15-0.3 mm, about 0.100 to about 0.200 mm, 0.3, 0.275, 0.25,
0.225, 0.2, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12, 0.11,
0.10, 0.09, 0.08 0.07, 0.06, 0.05, 0.04, 0.03, 0.02, or 0.01 mm.
The ultra-thin glass may be formed of glass, a glass ceramic, a
ceramic material or composites thereof. A fusion process (e.g.,
downdraw process) that forms high quality flexible glass can be
used in a variety of devices and one such application is flat panel
displays. Glass produced in a fusion process has surfaces with
superior flatness and smoothness when compared to glass produced by
other methods. The fusion process is described in U.S. Pat. Nos.
3,338,696 and 3,682,609. Other suitable glass forming methods
include a float process, updraw, down draw, press rolling, and slot
draw methods. Additionally, the flexible glass may also contain
anti-microbial properties by using a chemical composition for the
glass including an Ag ion concentration on the surface in the range
greater than 0 to 0.047 .mu.g/cm.sup.2, further described in U.S.
Patent Application Publication No. 2012/0034435 A1. The flexible
glass may also be coated with a glaze composed of silver, or
otherwise doped with silver ions, to gain the desired
anti-microbial properties, as further described in U.S. Patent
Application Publication No. 2011/0081542 A1. Additionally, the
flexible glass may have a molar composition of 50% SiO.sub.2, 25%
CaO, and 25% Na.sub.2O to achieve the desired anti-microbial
effects.
[0091] The terms "substantial," "substantially," and variations
thereof as used herein are intended to note that a described
feature is equal or approximately equal to a value or description.
For example, a "substantially planar" surface is intended to denote
a surface that is planar or approximately planar. Moreover,
"substantially" is intended to denote that two values are equal or
approximately equal. In some embodiments, "substantially" may
denote values within about 10% of each other, such as within about
5% of each other, or within about 2% of each other.
[0092] While particular embodiments have been illustrated and
described herein, it should be understood that various other
changes and modifications may be made without departing from the
spirit and scope of the claimed subject matter. Moreover, although
various embodiments of the claimed subject matter have been
described herein, such embodiments need not be utilized in
combination. It is therefore intended that the appended claims
cover all such changes and modifications that are within the scope
of the claimed subject matter.
* * * * *