This disclosure relates to a support bracket for a stack of containers, and more particularly, to a corner support assembly for aligning and supporting a stack of containers.
Current methods for packaging and shipping a plurality of containers can produce significant material waste and can include many processing steps before a shipment is ready to ship. However, consumers are expecting to pay less for shipping costs, though the costs associated with shipping related to materials and labor costs generally remain unchanged. To package and ship a stack of containers, a typical process includes first stacking the containers onto a pallet, wrapping the stack with plastic sheeting (e.g., plastic stretch wrap), and inserting corner bars between the stack and the plastic sheeting before the pallet supporting the stack of containers is moved. The corner bars are used to keep the stack of containers in alignment so that the pallet may be moved without the containers moving significantly relative to each other. The corner brackets are kept against the stack of containers by the plastic sheeting, and the entire stack may be shrink wrapped before shipping. When the pallet is unloaded, the shrink wrap and plastic sheeting are often discarded and cannot be used again.
In accordance with one or more exemplary aspects, a corner support assembly and/or method for stacking containers using a corner support assembly may provide a reusable and resilient apparatus for aligning stacked containers for packaging, maintaining alignment of the stacked containers during shipping, and/or protecting the containers from damage caused by clamp trucks, fork lifts, and other external forces. A corner support assembly disclosed herein includes a corner support bracket and a corner support bar. The corner support bracket is slidably coupled to the corner support bar and together form a corner support assembly that is adapted to attach to a corner of a stack of containers. One exemplary assembly may be placed at each corner of a stack of containers so that each corner of the stack is supported and aligned on the pallet during packaging and shipping.
In accordance with a first exemplary aspect, a corner support assembly for supporting a stack of containers may include a bar defining a corner and having a first end, a second end, and an interior surface. A bracket may be operatively coupled to the corner support bar. The bracket may include a front end spaced away from the bar and a back end facing the interior surface of the bar. The back end of the bracket may be disposed adjacent to the interior surface of the bar. The bracket may be disposed between the first end and the second end of the bar and may be oriented substantially perpendicular to the bar.
In accordance with a second exemplary aspect, a method of stacking containers using a corner support assembly may include placing a first container on a support surface. The first container may have a top surface, a bottom surface, and a corner. The bottom surface may be parallel to the support surface. The method may include placing a corner support assembly adjacent to the first container. The corner support assembly may include a bracket and a bar including a first end, a second end, and an interior side facing the corner of the first container. The bracket may be operatively coupled to the bar and may include a platform having a first surface and a second surface opposite the first surface. The second surface of the platform may be adjacent to the top surface of the first container.
In accordance with a third exemplary aspect, a corner support assembly for supporting a stack of containers may include a bar with a first arm, a second arm, and a corner connecting the first arm and the second arm at a right angle. The first arm, second arm, and corner may extend from a first end of the bar to a second end of the bar and may define an interior surface of the bar. A bracket may be slidably coupled to the first arm and the second arm of the bar. The bracket may include a platform having a first surface, a second surface, a back end, and a front end. The back end may be adjacent to the interior surface of the bar. The platform may be oriented substantially perpendicular relative to the bar. A first mount of the bracket may be proximally located to the front end of the platform. The first mount may be shaped to receive a portion of the first arm of the bar. A second mount may be proximally located to the front end of the platform. The second mount may be shaped to receive a portion of the second arm of the bar.
In accordance with any one or more of the foregoing first, second, or third exemplary aspects, a corner support assembly and a method of stacking containers using a corner support assembly may further include any one or more of the following preferred forms.
In a preferred form, the bar may include a first arm, a second arm, and the corner connecting the first and second arms.
In a preferred form, the bracket may be slidably coupled to the first arm and the second arm of the bar.
In a preferred form, the bracket may include a mount slidably coupled to the bar.
In a preferred form, the bracket may include a first side edge and a second side edge extending between the back end to the front end of the bracket.
In a preferred form, the first side edge may be oriented approximately 90 degrees relative to the second side edge.
In a preferred form, the mount may define a first hook disposed at the front end of the first side edge and a second hook disposed at the front end of the second side edge of the bracket.
In a preferred form, the bar may include an exterior surface opposite the interior surface.
In a preferred form, each of the first and second hooks may curve outwardly and away from the bracket and may include a portion that is disposed adjacent to the exterior surface of the bar when the bracket is operatively coupled to the bar.
In a preferred form, the mount of the bracket may define a channel disposed at the front end of the bracket.
In a preferred form, the channel may be sized to receive a portion of one of the first and second arms of the bar.
In a preferred form, the bracket may define a platform extending between the front end and the back end of the bracket and substantially perpendicular to the bar.
In a preferred form, at least one of the first and second side edges may extend perpendicularly relative to the platform to define a side wall.
In a preferred form, the front end of the bracket may have a first width and the back end of the bracket may have a second width.
In a preferred form, the first width may be greater than the second width.
In a preferred form, the back end of the bracket may be spaced away from the interior surface of the bar.
In a preferred form, the method may include placing a second container on the top surface of the first container.
In a preferred form, the second container may have a top surface, a bottom surface, and a corner.
In a preferred form, the bottom surface of the second container may be adjacent to the top surface of the first container and the corner of the second container may face the interior side of the bar.
In a preferred form, placing a corner support assembly adjacent to the first container may include inserting a front end of the bracket between the first container and the second container such that the first surface of the platform is adjacent to the bottom surface of the second container and the second surface of the platform is adjacent to the top surface of the first container.
In a preferred form, inserting the front end of the bracket between the first container and the second container may include placing the bracket on the top surface of the first container before placing the second container on the top surface of the first container.
In a preferred form, the method may include aligning the corner of the second container with the corner of the first container.
In a preferred form, the method may include adjusting a position of the bracket relative to the bar by sliding the bracket relative to the first end and the second end of the bar.
In a preferred form, the method may include placing a second corner support bracket assembly adjacent to the first container at a different corner of the first container.
In a preferred form, each of the first and second mounts may define a U-shaped channel to slidably receive a distal end of one of the first and second arms of the bar.
In a preferred form, a first side wall and a second side wall may be adjacent to the platform and may extend between the back end and the front end of the platform.
In a preferred form, the first side wall may define the first mount and the second side wall may define the second mount.
In a preferred form, the first side wall of the bracket may be parallel with the first arm of the bar. The second side wall of the bracket may be parallel with the second arm of the bar.
In a preferred form, the platform may be integrally formed with the first mount and the second mount.
In a preferred form, the back end of the platform may be spaced away from the interior surface of the bar.
In a preferred form, each mount of the first and second mounts may include a first surface and a second surface.
In a preferred form, the first surface of each of the first and second mounts may be coplanar with the first surface of the platform.
A corner support assembly 10 of the present disclosure is adapted to provide structural support, corner alignment, and corner protection to a stack of containers without requiring the stack of containers to be first secured by plastic sheeting. The example corner support assembly 10 may be easily coupled (e.g., attached, inserted, placed into) to a stack of containers without requiring the entire stack to be wrapped in plastic sheeting to hold the corner support assembly in place. A plurality of corner support assemblies can be used together to support a stack of containers at each corner of a four-cornered stack of containers. When supported at each corner, the stack of containers is less likely to shift out of alignment and tip over during packaging and shipping. The corner support assembly 10 facilitates the packaging and shipping process by reducing the number of steps needed to assemble, package, and ship a stack of containers. It may even be possible to avoid using any plastic wrap, since the corner support assembly 10 will tend to stay in place without wrapping for some types of stacks, though plastic wrapping provides additional stability. The wrap may be standard plastic sheeting that adheres to itself, or can be “shrink-wrap” that is later heated to give the stack additional strength and stability.
In
Referring particularly to the first corner assembly 10, the bar 14 is suspended above the shipping pallet 54 by the corner bracket 18, which is wedged in between first and second containers 60, 64. When the corner support assembly 10 is attached to the stack of containers 52, the bar 14 supports the corner 56 of the stacked containers 52, keeping the containers 52 in alignment (e.g., stacked on top of another) and from shifting or sliding relative to one another.
In the magnified view of
The corner 72 of the first container 60 abuts against the interior side 26 of the bar 14, but is not directly contacting the corner 74 of the second container 64 stacked above the first container 60. The weight of the second container 64 imparted on to the platform 30 of the bracket 18 and/or friction between the platform 30 and the first and second containers 60, 64 tend to keep the corner support assembly 10 in place within and against the stack 52.
The bracket 18 is spaced away from the joint 22 of the bar 14 by a gap G between the joint 22 of the bar 14 and the back end 80 of the bracket 18. The gap G provides space between the two stacked containers 60 and 64 in case the corners 72, 74 of the containers 60, 64 are dented or otherwise deformed. The gap G provides room for the containers at the corners where there might be some deformation in the container structure.
According to the teachings of the present disclosure, the bracket 18 of the corner support assembly 10 is adapted to slidably couple to the support bar 14 while maintaining its perpendicular orientation relative to the bar 14. As shown in
Each side edge of the first and second side edges 90, 92 includes a mount 94, 96, which is in the form of a mounting hook disposed at the front end 78 of the bracket 18. Each mounting hook 94, 96 of the first and second side edges 90, 92 protrudes from the platform 30 such that a portion 102, 104 of each mounting hook 94, 96 wraps around the edges of each arm 46, 48 of the bar 14 so that each hook 94, 96 is partially disposed adjacent to the exterior side 28 of the corner support bar 14 when the bracket 18 is attached to the bar 14. Each mounting hook 94, 96 of the bracket 18 is slidably coupled to the first arm 46 and the second arm 48, respectively, of the corner support bar 14. A U-shaped channel 106, 108 is defined by each mounting hook 94, 96 and is sized to receive a portion of one of the first and second arms 46, 48 of the corner support bar 14. In other examples, the bracket 18 may include only one mounting hook that slidably couples the bracket 18 to the bar 14.
As shown in
The mounting hooks 94, 96 may be coupled to the corner support bar 14 by a friction fit, such that the bracket 18 may slide in a vertical direction A (
In
In
The bracket 218 includes a first side edge 290 and a second side edge 292 adjacent to the platform 230, and the side edges 290, 292 extend from a back end 280 of the bracket 218 to a front end 278 of the bracket 218. First and second side walls 312, 314 extend away from a first surface 286 of the platform 230 and from a second surface 288 of the platform 230 at the side edges 290, 292. The first and second side walls 312, 314 are rectangular members and may be integrally formed with the platform 230 or may be formed separately and then attached to the platform 230 by welding or other equally suitable method. The platform 230 is perpendicularly disposed relative to each side wall 312, 314 and is centrally disposed relative to a height of the side walls 312, 314.
In
The platform 430 of the third exemplary bracket 418 includes a first surface 486 and a second surface 488, a first edge 490, and a second edge 492. Unlike the first and second exemplary brackets 18, 218 illustrated in
The bracket 418 includes a first side flange 518 and a second side flange 520 disposed at a front end 478 of the bracket 418 to mount the bracket 418 to the support bar 14. The first side flange 518 defines a U-shaped channel 506 sized to receive a portion, and specifically a distal end 46A, of the first arm 46 of the bar 14. The second side flange 520 defines a U-shaped channel 508 sized to receive a portion, and specifically a distal end 48A of the second arm 48 of the bar 14. The first and second side flanges 518, 520 extend axially away from the first surface 486 of the platform 430 and the second surface 488 of the platform 480. Unlike the side walls 312, 314 of the second exemplary bracket 218, the flanges 518, 520 of the third exemplary bracket 418 do not extend the entire length of each side edge 490, 492 of the bracket 418. The flanges 518, 520 may be attached to the bracket 418 by welding, adhesive, or other suitable methods, or may be integrally formed with the platform 430 of the bracket 418. In some examples, an interior surface of the each flange 518, 520 may be coated with a material to help grip the arms 46, 48 of the support bar 14 when the bracket 418 is coupled to the bar 14. In other examples, the flanges 518, 520 may be a flexible or deformable material and are configured to slightly change shape to grip a variety of shapes and sizes of the support bar 14.
The step 630 of placing the corner support assembly 10 adjacent to the first container 60 may include inserting the platform 30 of the bracket 18 after the second container 64 is placed on top of the first container 60 of the stack of containers 52. The platform 30 of the bracket 18 is placed in between the first container 60 and the second container 64 so that the first surface 86 of the platform 30 is adjacent to the bottom surface 124 of the second container 64 and the second surface 88 of the platform 30 is adjacent to the top surface 118 of the first container 60. More particularly, the platform 30 may be inserted between the corner 72 of the first container 60 and the corner 74 of the second container 64. Alternatively, the method of 600 may include placing the bracket 18 in between the first container 60 and the second container 64 by placing the bracket 18 on the top surface 118 of the first container 60 before placing the second container 64 on the top surface 118 of the first container 60.
A step 640 of the method 600 may include aligning the first and second containers 60, 64 with the assembly 10. This step 640 may include aligning the corner 72 of the first container 60 and the corner 74 of the second container 64 and then placing the interior side 26 of the support bar 14 adjacent to the corner 72 of the first container 60 and the corner 74 of the second container 64. Further, a step 650 of the method 600 may include adjusting a position of the bracket 18 relative to the corner support bar 14 by sliding the bracket 18 relative to the first end 34 and the second end 38 of the corner support bar 14. This step 650 may occur before inserting the bracket 18 between the first and second containers 60, 64 Moreover, the method 600 may include attaching a second corner support bracket assembly 12 to the stack of containers 52. The second corner support bracket assembly 12 may be attached to a different corner 66 of the stack of containers 52. However, in another example, a corner support bracket assembly 12 may be placed vertically above the first corner support bracket assembly 10 at the same corner 56 of the stack 52. As shown in
Using the corner support assembly 10 of the present disclosure in the packaging and shipping process may help reduce waste associated with packaging and shipping. To ensure the stack can be moved and transported without the individual containers shifting relative to one another, the corner support assembly 10 should be placed between containers to maintain the alignment of the stack 52 during each step of packaging and shipping process. The corner support assembly 10 is also reusable and may be adjusted according to different size stacks. The exemplary brackets 18, 218, 418, as described earlier, are slidable coupled relative to the corner support bar 14. Each of the exemplary brackets 18, 218, 418 may be inserted first between two containers 60, 64 of the stack 52 and the support bar 14 may be subsequently adjusted by sliding the support bar 14 in the vertical direction relative to the bracket 18. Alternatively, a user may attach multiple brackets to a single support bar 14 prior to attaching the assembly 10 to the stack of containers 52 for additional support. The position of the bracket 18, 218, 418 relative to the support bar 14 may be adjusted to account for changes in the stack 52, e.g., containers are removed or added to the stack 52. The corner support bar 14 is shaped to form an extruded right-angle bar. In the present example, the corner support bar 14 forms a right-angle to abut against a stack of rectangular containers 52. However, the support bar 14 may be shaped to abut against an irregular shaped stack, for example, a plurality of containers stacked in a triangular column. In this example, the corner support bar 14 may be shaped to provide an angle to fit a triangular corner. In yet another example, the interior surface 26 of the support bar 14 may have a radius of curvature to abut against a stacked, rounded column of containers.
The figures and description provided herein depict and describe preferred embodiments of a corner support bracket assembly for purposes of illustration only. One skilled in the art will readily recognize from the foregoing discussion that alternative embodiments of the components illustrated herein may be employed without departing from the principles described herein. Thus, upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs of a corner support bracket. Thus, while particular embodiments and applications have been illustrated and described, it is to be understood that the disclosed embodiments are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the methods and components disclosed herein without departing from the spirit and scope defined in the appended claims.
Number | Date | Country | |
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62636743 | Feb 2018 | US |