Patent Application
20120080347
This application is a continuation-in-part of U.S. patent application Ser. No. 12/894,768, filed Sep. 30, 2010, entitled, “Container For Shipping Fragile Products and Method For Making The Same,” which is incorporated by reference herein in its entirety.
The field of the invention relates generally to a container for shipping frangible and fragile articles and more particularly, to a container for transporting a plurality of curved glass sheets, such as windshields for vehicles.
Containers for shipping glass or plexiglass sheets, such as windshields used in automobiles and trucks, are typically corrugated structures or wood crates (or a combination thereof) supported on a wood pallet. The containers are preassembled or occasionally shipped in components to the windshields manufacturer and are set up or assembled on-site. In at least some known glass shipping containers, bottom support and side devices include sufficient features to securely support the glass and withstand the rigors of transportation and be capable of stacking to maximize warehouse space. This includes providing a snug fit for the glass. Further, in at least some known glass shipping containers, the bottom support and side devices are constructed to at least partially withstand banding pressures from straps or bands utilized in shipping.
In at least some known cases, shipping the glass sheets in an upright position increases a propensity for the glass sheets to shift during transit, thereby stressing the banding and the portions of the container in contact with the banding. Such increased wear may decrease a life expectancy of the shipping container, and may allow for some shifting of the glass sheets resulting in at least some damage to the glass, as well as the shipping container. Moreover, some glass shipping containers provide for placing the glass sheets directly on the bottom pallet, wherein localized induced weight stresses may shorted an expected lifespan of the shipping container's bottom pallet. Further, the positioning of banding around the container is often performed in a haphazard manner because the container does not provide adequate access for routing the banding when the container is at least partially loaded with windshields.
In one aspect, a container for transporting glass sheets is provided. The container defines an internal volume. The container includes a bottom structure and a back wall extending upwardly from the bottom structure. The container also includes a first side wall coupled to the back wall and extending upwardly from the bottom structure. The container further includes a second side wall opposite the first side wall coupled to the back wall and extending upwardly from the bottom structure. The container also includes a back support structure coupled to the back wall and configured to constrain a plurality of glass sheets. The back support structure includes at least one back support member. The at least one back support member extends in a substantially vertical direction. The back support member also includes at least one offset member. The offset member includes a first side defining a first length extending inwardly a first distance from the at least one back support member toward the internal volume of the container. The offset member also includes a second side defining a second length extending inwardly a second distance from the at least one back support member toward the internal volume of the container. The second length is greater than the first length. The back support member further includes at least one foam rail coupled to a foam rail support member. The foam rail support member is coupled to the at least one offset member.
In another aspect, a method of assembling a container for transporting glass sheets is provided. The container defines an internal volume. The method includes providing a bottom structure having a front edge and coupling a back wall to the bottom structure and extending the back wall upwardly therefrom. The method also includes coupling a first side wall to the back wall and extending the first side wall upwardly from the bottom structure. The method further includes coupling a second side wall to the back wall and extending the second side wall upwardly from the bottom structure, wherein the first and second side walls are opposite to each other. The method also includes coupling at least one back support member to the back wall and extending the at least one back support member in a substantially vertical direction. The method further includes forming ay least one offset member that includes forming a first side of the at least one offset member having a first length and forming a second side of the at least one offset member having a second length. The second length is greater than the first length. The method also includes coupling the at least one offset member to the at least one back support member such that the first side extends inwardly a first distance from the at least one back support member toward the internal volume of the container, and the second side extends inwardly a second distance from the at least one back support member toward the internal volume of the container. The method further includes coupling a foam rail support member to the at least one offset member. The method also includes coupling at least one foam rail to the foam rail support member.
The following detailed description illustrates the disclosure by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and use of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure. The orientations as used herein are referenced to a horizontal, or x-axis 10, a vertical, or y-axis 20, and a depth, or z-axis 30.
The term “glass sheets” as used herein includes sheets made from plexiglass, glass, plastic, or other similar frangible or fragile materials, and/or combinations thereof, which are typically used to make windshields or other windows for vehicles, or glass sheets for any other application. While the windshields as alluded to herein are typically curved, the shipping container described herein may be used with glass sheets of any configuration and/or orientation.
The present invention provides a glass shipping container formed from a plurality of wooden members and corrugated cardboard. The shipping container includes a bottom, or floor support mechanism that facilitates supporting the transported glass sheets above a bottom support pallet. The floor support mechanism also enables banding straps to be routed around the glass sheets, through holes and grooves formed in an oriented strand board (OSB) member, and to an outer anchoring portion of the shipping container, thereby improving the loading and securing the glass sheets therein. The floor support mechanism is further configured to strengthen the shipping container while shifting induced weight forces though the reinforced portions of the OSB member and to a reinforced portion of the bottom support pallet. The shipping container also includes an inclined back support mechanism. Specifically, the inclined back support mechanism is angled with respect to one dimension to facilitate stacking glass sheets within the shipping container such that a substantial portion of the induced weight forces are transferred to the rear of the shipping container. Also, the inclined back support mechanism is angled with respect to another dimension to facilitate accommodating the curvature of the windshields. The shipping container further includes a top support member that strengthens the shipping container and reduces the potential for damage to the glass sheets during transport.
Referring now to the drawings, and more specifically to
In general, in the embodiments described herein, heat-treated soft wood, that is, southern yellow pine, is used for the wooden components unless otherwise stated. Alternatively, any wood materials that enable operation of shipping container 100 as described herein are used.
In the exemplary embodiment, front panel 102 includes an upper support member 130 and back panel 120 includes an upper support member 132 that is substantially parallel to support member 130, that is, substantially horizontal. Support members 130 and 132 are fabricated from substantially unitary 2-inch by 4-inch wood, that is, a 2×4. Also, in the exemplary embodiment, each of sidewalls 112 includes a support member 134, wherein both support members 134 are substantially parallel to each other. Support members 134 are fabricated from substantially unitary 2-inch by 2.25-inch wood, that is, a 2×2-¼ and are coupled to support members 130 and 132 by standard fastening mechanisms (not shown) that include, without limitation, screws, bolts, and nails. Support members 130, 132, and 134 define a substantially open top arrangement for shipping container 100. Moreover, in the exemplary embodiment, back panel 120 is coupled to support members 132 and 134 via a plurality of staples 138. Alternatively, back panel 120 is coupled to support members 132 and 134 by standard fastening mechanisms (not shown) that include, without limitation, staples, screws, bolts, and nails.
Also, in the exemplary embodiment, glass shipping container 100 includes two back support mechanisms 144. Alternatively, any number of back support mechanisms 144 is used to enable operation of shipping container 100 as described herein, including, without limitation, one and three mechanisms 144. In the exemplary embodiment, each back support mechanism 144 is an angled backrest that has an approximately five degree incline (not shown in
Each back support mechanism 144 also includes a foam rail support member 162 (shown in phantom in
Further, in the exemplary embodiment, glass shipping container 100 includes a plurality of rear corner vertical support members 170, wherein each support member 170 is a unitary 2×2-¼ wooden member. Each support member 170 is coupled to corrugated cardboard wall 121 and a side panel 140 by any means that enables operation of shipping container 100 as described herein including, without limitation, staples and adhesives. Moreover, shipping container 100 includes a plurality of upper horizontal side support members 172 and a plurality of lower horizontal side support members 174. Each of support members 172 and 174 is also a unitary 2×2-¼ wooden member that is coupled to a support member 170 by any means that enables operation of shipping container 100 as described herein including, without limitation, fastening hardware and adhesives. Each of members 172 and 174 may be coupled to a side panel 140 by any means that enables operation of shipping container 100 as described herein including, without limitation, staples and adhesives. Furthermore, each upper horizontal side support member 172 is coupled to an adjacent sidewall support member 134 and each horizontal side support member 174 is coupled to bottom support pallet 106, wherein such coupling is performed by any means that enables operation of shipping container 100 as described herein including, without limitation, fastening hardware and adhesives.
Moreover, in the exemplary embodiment, glass shipping container 100 includes a plurality of front corner vertical support members 176, wherein each support member 176 is a unitary 2×2-¼ wooden member. Each support member 176 is coupled to one support member 172 and one support member 174 by any means that enables operation of shipping container 100 as described herein including, without limitation, fastening hardware and adhesives. Support members 176 may be coupled to a side panel 140 and front portion sidewalls 114 by any means that enables operation of shipping container 100 as described herein including, without limitation, staples and adhesives.
Use of unitary 2×2-¼ wooden members for support members 170, 172, 174, and 176 facilitate increasing a storage/shipping region within glass shipping container 100 and access thereto in contrast to standard wooden 2×4s and 2×3s. Moreover, sidewalls 114 may or may not include additional support members.
Also, in the exemplary embodiment, glass shipping container 100 includes floor support mechanism 180. Floor support mechanism 180 includes a floor support member, that is, a horizontal support board 182 that is fabricated from oriented strand board (OSB) material, wherein OSB material provides sufficient strength and durability for repeated shipping use with a relatively low cost as compared to other materials, such as plywood and plastic. Horizontal support board 182 is coupled to bottom support pallet 106 by any means that enables operation of shipping container 100 as described herein including, without limitation, fastening hardware and adhesives. Also, horizontal support board is substantially laterally centered on pallet 106 and extends approximately from back panel 120 to front panel 102.
Floor support mechanism 180 also includes at least one of unitary 1×4 wooden foam rail support member 184 (two shown in phantom in
Floor support mechanism 180 further includes at least one foam rail 185 that extends proximately from vertical foam rails 164. Foam rail 185 is coupled to a foam rail support member 184 by any means that enables operation of shipping container 100 as described herein including, without limitation, fastening hardware and adhesives. Further, in the exemplary embodiment, glass shipping container 100 includes two rail support members 184 and two foam rails 185. Alternatively, any number of support members 184 and rails 185 are used to enable operation of shipping container 100 as described herein, including, without limitation, one and three. In the exemplary embodiment, foam rail support member 182 extends to a point between a front edge (not shown in
Floor support mechanism 180 further includes a plurality of banding guide channels, or grooves 186 that are operatively coupled to a plurality of banding access apertures, or holes 188, wherein both grooves 186 and holes 188 are defined within horizontal support board 182. Further, grooves 186 define banding apertures 128, therefore apertures 128 are also defined in horizontal support board 182. Therefore, holes 188 are operatively coupled to apertures 128 via grooves 186, facilitate channeling banding 126 throughout the bottom portion of glass shipping container 100, thereby facilitating support of glass sheets (not shown) therein throughout transit. One embodiment of shipping container 100 includes two holes 188 for each groove 186, wherein each grove is inboard from, and adjacent to, a foam rail 184. An alternative embodiment of shipping container 100 includes three holes 192 for a single groove 190, wherein both holes 192 and groove 190 are aligned about an approximate center of horizontal support board 182. Further, alternatively, any number of holes 188 and 192 and any number of grooves 186 and 190 are formed within horizontal support board 182 that enables operation of shipping container 100 as described herein.
In the exemplary embodiment, each back support mechanism 144 includes a first, or upper offset member 302. Upper offset member 302 includes a first side 304 and a second side 306. First side 304 and second side 306 are substantially parallel to y-axis 20. First side 304 has a first outside length 308 and second side 306 has a first inside length 310, wherein both lengths 308 and 310 extend from vertical back support member 160 into the interior volume of shipping container 100. First inside length 310 is greater than first outside length 308. Moreover, first outside length 308 and first inside length 310 have length values that define an angle 312 with respect to x-axis (10) in the x-z plane. Also, in the exemplary embodiment, angle 312 has a value in a range between approximately 3 degrees and approximately 5 degrees, with a preferred angle of approximately 4 degrees, to facilitate acceptance of the curvature of windshields (not shown). Alternatively, angle 312 has any value that enables operation of glass shipping container 100 as described herein. Upper offset member 302 is coupled to vertical back support member 160 by any means that enables operation of shipping container 100 as described herein including, without limitation, fastening hardware and adhesives, proximate to a top of foam rail support members 162 and foam rails 164.
Back support mechanism 144 also includes a second, or lower offset member 314. Lower offset member 314 includes a first side 316 and a second side 318. First side 316 and second side 318 are substantially parallel to y-axis 20, and are parallel to sides 304 and 306, respectively, of upper offset member 302. Moreover, first side 316 and second side 318 are at least partially coincidental with planes defined by sides 304 and 306, respectively. First side 316 has a second outside length 320 and second side 318 has a second inside length 322, wherein both lengths 320 and 322 extend from vertical back support member 160 into the interior volume of shipping container 100. Second inside length 322 is greater than second outside length 320. Also, second inside length 322 is greater than first inside length 310 and second outside length 320 is greater than first outside length 308. Moreover, second outside length 320 and second inside length 322 have length values that cooperate with first outside length 308 and first inside length 310, respectively, to define angle 312 with respect to x-axis (10) in the x-z plane.
In addition to defining angle 312, first outside length 308, second outside length 320, first inside length 310, and second inside length 322 have values that define each back support mechanism 144 as an angled backrest. Upper offset member 302 and lower offset member 314 define an incline, or offset angle 322 with respect to y-axis 20 in the y-z plane. In the exemplary embodiment, offset angle 322 has a value of approximately five degrees. Alternatively, offset angle 322 has any value that enables operation of shipping container 100 as described herein.
Lower offset member 314 rests upon and is coupled to horizontal support board 182 by any means that enables operation of shipping container 100 as described herein including, without limitation, fastening hardware and adhesives. Also, lower offset member 314 rests against vertical back support member 160 such that lower offset member 314 is coupled to vertical back support member 160 by a pressure, or friction fit. Alternatively, lower offset member 314 is coupled to vertical back support member 160 by any means that enables operation of shipping container 100 as described herein including, without limitation, fastening hardware and adhesives.
Also, in the exemplary embodiment, offset members 302 and 314 are unitary wooden members. Alternatively, offset members 302 and 314 have any configuration that enables operation of shipping container 100 as described herein including, without limitation, at least one portion of a 2×4 or a plurality of portions of 2×4 coupled together. Moreover, offset members 302 and 314 have any shape that enables operation of shipping container 100 as described herein including, without limitation, rectangular and trapezoidal.
Foam rail support member 162 is coupled to each of upper and lower offset members 302 and 314, respectively, as shown by arrow 324 and foam rail 164 is coupled to support member 162 as shown by arrow 326, thereby inclining foam rail support member 162 and foam rail 164 by offset angle 322. Inclined back support mechanism 144 facilitates stacking glass sheets (not shown) within shipping container 100 such that a substantial portion of induced weight forces are transferred to a rearward portion of shipping container 100.
Each back support mechanism 209 also includes a foam rail support member 211 coupled to at least one of corrugated cardboard wall 121, back support member 132, and/or floor support mechanism 180 by any means that enables operation of shipping container 100 as described herein. Each foam rail support member 211 is a wooden 2-inch by 6-inch member, that is, a wooden 2×6 that extends from horizontal back support member 132 to floor support mechanism 180. Each back support mechanism 209 further includes at least one foam rail 215 coupled to foam rail support member 211 as shown by arrow 213 by any means that enables operation of shipping container 100 as described herein including, without limitation, fastening hardware and adhesives. Each foam rail 215 extends from a predetermined distance below horizontal back support member 132 to floor support mechanism 180.
In the exemplary embodiment, both horizontal support board 182 and bottom support pallet 106 have a first length L1 that defines a first distance D1 from back panel 120 to an outer front edge 218 of bottom support pallet 106. Also, in the exemplary embodiment, foam rail support member 184 has a second length L2 that defines a second distance D2 from back panel 120 and foam rail support member 184 includes an outer edge 216 that is proximate to outer front edge 218. Edges 216 and 218 and distances D1 and D2 define a distance 220 therebetween. Moreover, foam rail 186 has a third length L3 that defines a third distance D3 from back panel 120 and foam rail 186 includes an outer edge 222 that defines a distance 224 between edges 222 and 216 and D2 and D3. Distance 224 facilitates shifting induced weight forces from substantially transferring to horizontal support board 182 to transferring to a more robust portion of bottom support pallet 106 within distance 224. Furthermore, such stresses are shifted away from a portion of OSB horizontal support board 182 in the vicinity of banding guide holes 188, wherein an ability to withstand such stresses may be diminished, that is, a predetermined distance 226 between a front-most hole 188 and edge 216 of foam rail support member 184. Distances 220, 224, and 226 have any values that enable operation of shipping container 100 as described herein.
The above-described container provides a glass shipping container formed from a plurality of wooden members and corrugated cardboard. More specifically, the shipping container as described herein includes a bottom, or floor support mechanism that facilitates supporting the transported glass sheets above a bottom support pallet. Also, the floor support mechanism enables banding straps to be routed around the glass sheets, through holes and grooves formed in an oriented strand board (OSB) member, and to an outer anchoring portion of the shipping container, thereby improving the loading and securing the glass sheets therein. Further, specifically, the floor support mechanism is configured to strengthen the shipping container while shifting induced weight forces though the reinforced portions of the OSB member and to a reinforced portion of the bottom support pallet. Moreover, the shipping container as described herein includes an inclined back support mechanism. Specifically, the inclined back support mechanism is angled with respect to one dimension to facilitate stacking glass sheets within the shipping container such that a substantial portion of the induced weight forces are transferred to the rear of the shipping container. Also, the inclined back support mechanism is angled with respect to another dimension to facilitate accommodating the curvature of the windshields. The shipping container as described herein further includes a top support member that strengthens the shipping container and reduces the potential for damage t the glass sheets during transport.
Exemplary embodiments of a container formed to contain glass sheets therein are described above in detail. The container is not limited to the specific embodiments described herein, but rather, components of the container may be utilized independently and separately from other components described herein. For example, the container features may also be used in combination with other types of containers, and is not limited to practice with only rectangular containers, as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other container applications.
Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12894768 | Sep 2010 | US |
| Child | 13207095 | US |
