Disposable And Reusable Spaceer Rack, And Method Of Using Same

Abstract

A disposable and reusable spacer rack apparatus, for cooperating with a pallet to support a stack of thin sheets of printable stock thereon. A spacer rack apparatus according to the invention includes a body member, having an upper surface and a substantially flat lower surface. The body member has a series of parallel spaced apart grooves formed in an upper portion thereof, defining a plurality of parallel spaced apart divider slats between the grooves. The body member is of a first height at the divider slats, and is of a second, reduced height in the area of the grooves. The grooves are provided for receiving support rods during a printing stock changeover process. In a preferred embodiment of the invention, the spacer rack apparatus is integrally formed as a single unit, out of relatively inexpensive materials, such as cardboard, fiberboard, recycled plastic, or open-celled plastic foam. The invention also includes a method of using the spacer rack apparatus.

Description

Summary of Invention

[0019] The present invention provides a disposable and reusable spacer rack apparatus for cooperating with a pallet to support a stack of printing paper thereon. A spacer rack apparatus according to a first embodiment of the present invention, generally, includes a substantially rectangular body member, the body member including a substantially flattened base portion having an upper surface and a lower surface, and a plurality of parallel spaced apart divider slats attached to the upper surface of the base portion. The parallel spaced apart divider slats define a plurality of open grooves therebetween, for receiving support rods therein during a paper change process.

[0020] In a preferred embodiment of the present invention, the spacer rack apparatus is integrally formed as a single unit, out of relatively inexpensive materials, such as cardboard, recycled plastic, or open-celled plastic foam.

[0021] A spacer rack apparatus according to a second preferred embodiment of the present invention is formed from a sandwich-type intermediate body in a machining operation. The intermediate body includes an upper facing which is a first thin sheet of material, a lower facing which is a second thin sheet of material substantially identical to the upper facing and oriented parallel thereto, and a central core, which is disposed between the upper and lower facings and is attached thereto. The central core is formed from a matrix material including wall sections oriented substantially transverse to the upper and lower facings. The central core may be formed in a hexagonal honeycomb pattern, with cells thereof having a diameter of between ½inch and 3/4 inch in diameter.

[0022] Accordingly, it is an object of the present invention to minimize the amount of labor required for re-stocking a continuous feed type of printing press with paper.

[0023] It is a further object of the present invention to provide a method and apparatus for restocking a printing press with paper, which would allow re-stocking during operation thereof, but which would obviate the necessity for manually unloading and re-stacking the paper.

[0024] It is yet a further object of the present invention to provide a less expensive alternative to the customized grooved skid which is currently used to load paper into the above-described type of printing press.

[0025] For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in conjunction with the accompanying drawings. Throughout the following detailed description and in the drawings, like numbers refer to like parts.

Brief Description of Drawings

[0026] Figure 1 is a perspective view of a disposable and reusable spacer rack according to a first embodiment of the present invention, sitting atop a pallet;

[0027] Figure 2 is a front plan view of the pallet and spacer rack of Figure 1, shown with a stack of paper thereon;

[0028] Figure 3A is a detail view of the spacer rack and pallet of Figure 1, taken inside the circle labeled 3 in Figure 1, and showing a first possible construction of the spacer rack;

[0029] Figure 3B is a detail view of the spacer rack and pallet of Figure 1, taken inside the circle labeled 3 in Figure 1, and showing a second possible construction of the spacer rack;

[0030] Figure 4 is a perspective view of a disposable and reusable spacer rack according to a second embodiment of the present invention, with grooves thereof shown parallel to a line-of-sight viewing direction;

[0031] Figure 5 is a top plan view of the spacer rack of Figure 4;

[0032] Figure 6 is a side plan view of the spacer rack of Figure 4;

[0033] Figure 7 is an end plan view of the spacer rack of Figure 4;

[0034] Figure 8 is a bottom plan view of the spacer rack of Figure 4;

[0035] Figure 9 is a perspective view of the disposable and reusable spacer rack of Figure 4, with the grooves thereof shown perpendicular to a line-of-sight viewing direction;

[0036] Figure 10 is a detail perspective view of a corner part of the spacer rack of Figure 4;

[0037] Figure 11 is a detail perspective view of a corner part of an intermediate member which is used to form the spacer rack of Figure 4;

[0038] and Figure 12 is a top plan view of a cut away portion of a central core layer of the intermediate member of Figure 11.

Detailed Description

[0039] FIRST EMBODIMENT

[0040] Referring now to Figures 1-3B of the drawings, a disposable and reusable low cost spacer rack apparatus, according to a first embodiment of the present invention, is shown generally at 10. The spacer rack apparatus 10 hereof is shown placed on top of a pallet 12, and is provided for cooperating with a pallet 12 to support a stack 14 of printing paper thereon. As used herein, the term "pallet" broadly indicates pallets (which typically have top and boards with runners therebetween), skids (which typically have only top boards supported on runners), and other such supporting devices.

[0041] Throughout the present specification, numerous references are made to paper, stacks of paper, and the like. It will be understood by those skilled in the relevant art that the present invention may be used with card stock, with transparent or opaque plastic sheets, or with other thin sheets of printable stock material to be printed on in a printing press. As used throughout the present specification, the term 'paper' is not intended to be interpreted as a limitation on how the invention may be used, but rather is provided as an illustration, since paper is the most commonly used type of printing stock.

[0042] The pallet 12 is of generally conventional construction, although it is preferred to be kept to a higher standard of quality than some pallets which are available. The length and width dimensions of the spacer rack apparatus are approximately the same as those of the upper surface of the pallet 12, so as to fit easily thereon. The pallet 12 may be made of wood or plastic. The pallet 12 is constructed so as to define open channels 36 therein for receiving the tines (not shown) of a hand truck, forklift, or similar lifting mechanism therein.

[0043] The spacer rack apparatus 10 normally is insufficient in strength and durability to function as a sole support for a stack of blank paper or other printing stock, especially for purposes of handling and transportation thereof, but the spacer rack apparatus hereof is not required to be self-supporting, or to have great strength and durability, because it is used together with the conventional pallet 12, which provides strength and durability to the combination 15 of the pallet and spacer rack. Moreover, the spacer rack 10 can be made very inexpensively, as discussed further hereinbelow, because it is not required to be self-supporting. The ability to make the spacer rack 10 inexpensively is very desirable because the rack may, as a practical matter, be disposed of after only a single use. Of course, the spacer racks 10 may be reused, if desired, at the discretion of the user. If the spacer racks 10 are intended to be reused, they may be made a little more durable than if they are intended to be discarded.

[0044] A spacer rack apparatus 10 according to the present invention, generally, includes a substantially rectangular body member 16. The body member 16 includes a substantially flattened base portion 18 having an upper surface 20 and a lower surface 22. The body member 16 also includes a plurality of parallel spaced apart divider slats 24, which are attached to the upper surface 20 of the base portion 18. In one embodiment, the divider slats 24 are about 1/2" to 1 inch wide, and substantially the same height as they are wide, as shown.

[0045] The parallel spaced apart divider slats 24 define a plurality of parallel open grooves 26 therebetween, for receiving support rods (not shown) during a paper change process. The grooves 26 are about the same width as the divider slats 24. The body member 16 may include extra wide slats 28, 30 at opposite side edges thereof, as shown for strength and reinforcement.

[0046] The base portion 18 and the slats 24 may be constructed separately, and connected together with appropriate bonding or fastening means such as nails, staples and/or glues or other adhesives. Alternatively, the base portion 18 and slats 24 may be integrally constructed as a single unitary member. In either case, the materials used are preferably inexpensive, such as wood, plastic, plastic foam, cardboard, fiber board, pressboard, or the like.

[0047] In a preferred embodiment of the present invention, the spacer rack apparatus 10 is integrally formed as a single unit, out of relatively inexpensive materials, such as cardboard, fiber board, recycled or recyclable plastic, or plastic foam.

[0048] As shown in Figure 3A, the spacer rack apparatus 10 could be made of cardboard 32. Alternatively, the spacer rack apparatus 10 could be made of chopped paper or fiberboard. As yet another alternative, and as shown in Figure 3B, the spacer rack apparatus 10 could be molded out of an open-celled plastic foam 34.

[0049] SECOND EMBODIMENT

[0050] Referring now to Figures 4-10 of the drawings, a disposable and reusable low cost spacer rack apparatus, according to a second embodiment of the present invention, is shown generally at 210. The spacer rack apparatus 210 hereof is preferably made of corrugated cardboard material and, as in the first embodiment, is intended for placement on top of a pallet 12, and is provided for cooperating with the pallet 12 to support a stack 14 of printing paper thereon. As used herein, the term "pallet" broadly indicates pallets (which typically have top and boards with runners therebetween), skids (which typically have only top boards supported on runners), and other such supporting devices.

[0051] The spacer rack apparatus 210 normally is insufficient in strength and durability to function as a sole support for a stack of blank paper or other printing stock, especially for purposes of handling and transportation thereof, but the spacer rack apparatus hereof is not required to be self-supporting, or to have great strength and durability, because it is used together with the conventional pallet 12, which provides strength and durability to the combination of the pallet and spacer rack. Moreover, the spacer rack 210 can be made very inexpensively, as discussed further hereinbelow, because it is not required to be self-supporting. The ability to make the spacer rack 210 inexpensively is, again, very desirable because the rack may, as a practical matter, be disposed of after only a single use. Of course, the spacer racks 210 may be reused, if desired, at the discretion of the user. If the spacer racks 210 are intended to be reused, they may be made a little more durable than if they are intended to be discarded.

[0052] The spacer rack apparatus 210 according to the second embodiment of present invention, is formed out of an intermediate member 211 (Figure 11) which is generally a substantially rectangular body member having a sandwich-like configuration. The intermediate member 211 includes a substantially flat sheet-like upper facing 215, a substantially flat sheet-like lower facing 217 parallel to the upper facing, and a central core 219 disposed between the upper and lower facings. The upper and lower facings 215, 217 are attached to the central core 219 and are preferably glued thereto. The upper and lower facings 215, 217, and the central core 219 are preferably all formed of cardboard material.

[0053] The central core 219 is preferred to be made as a honeycomb-like matrix of regularly spaced hexagonal cells connected together, as shown in Figure 12. The cells are preferably of a diameter between ½and 1 inch in diameter. 3/4" diameter cells are the most preferred.

[0054] In forming the spacer rack 210 out of the intermediate member 211, a machine tool (not shown) is used to punch-cut and crush down selected areas of the upper facing 215 and part of the central core 219, to form grooves 226 in the upper surface thereof, thereby transforming the intermediate member 211 of Figure 11 into the finished spacer rack of Figures 4-10. The machine tool includes parallel spaced apart blades which cut parallel slits through the upper facing 215 in the area of the grooves 226. The machine tool further includes a flat crushing section between the blades, which pushes downwardly on a cut-away strip portion of the upper facing 215, and which compresses part of the central core 219 to a selected depth in the body member 216. After the machine tool has formed the grooves 226 in the body member 216, the cut-away strip portion of the upper facing 215 which has been moved downwardly in the body member 216 defines a floor 220 at the bottom of the groove.

[0055] The crushing down of the grooves 226, in the body member 216, also defines a plurality of parallel spaced apart divider slats 224, in the areas of the body member which remain uncompressed. Taken together, the upper surface of all of the divider slats 224 defines an upper support surface 225 of the spacer apparatus 210 for supporting a plurality of thin sheets of printable stock thereon. In one embodiment, the divider slats 224 are about 1/2" to 1 inch higher than the floor 220, and are made in varying widths according to a predetermined pattern. The total height of the spacer apparatus 210 is between 1 and 2 inches. After the crushing operation, selected portions of the central core 219 remain compressed in the area of the grooves 226, and selected portions of the upper facing 215 define floor portions 220 at the bottom of the grooves.

[0056] The resultant structure, as shown in is preferably one in which the floor portions 220 of the sheet body 216, in the area of the grooves 226, is substantially flat and horizontally oriented. The adjacent walls 234, 236, on opposite sides of the grooves 226, are corrugated rather than being completely flat, are substantially vertically oriented, and are disposed along planes which are substantially parallel to one another, and which are substantially perpendicular to the floor 220.

[0057] The parallel spaced apart divider slats 224 are spaced between the plurality of parallel open grooves 226. The grooves 226 are provided for receiving support rods (not shown) during a paper change process. The grooves 226 are about 1/2" to 1 inch wide by 1/2" to 1" deep.

[0058] The body member 216 may include extra narrow outer slats 228, 230 at opposite side edges thereof, as shown, to conserve material.

[0059] METHODS OF USE

[0060] In a first method of using a spacer rack apparatus according to the present invention, an initial step is obtaining a stack assembly 40 which includes a pallet 12 with a spacer rack 10 as described herein disposed on top of the pallet, and a paper stack 14 disposed on the spacer rack, as shown in Figure 2. The next step in the method is placing the pallet 12, with the spacer rack 10 and paper stack 14 thereon, on a movable platform of a printing press, and operating the printing press to use individual sheets of paper from the stack while moving the platform vertically upwardly. The next step in the method is inserting a plurality of support rods into, and through, the grooves 26 of the spacer rack and attaching them to a fixed portion of the printing press behind the platform. The next step in the method is lowering the platform downwardly, while supporting the remaining paper stack on the support rods. The final step in the first method hereof is removing the pallet and support rack from the platform. The sequence of steps is repeated, as desired, to provide continuous operation of the printing press. The method according to the present invention may include a further step of disposing of the spacer rack 10. Alternatively, the method according to the present invention may include a further step of sending the spacer rack 10 to a paper manufacturer or supplier, to be reused.

[0061] Although the present invention has been described herein with respect to a preferred embodiment thereof, the foregoing description is intended to be illustrative, and not restrictive. Those skilled in the art will realize that many modifications of the preferred embodiment could be made which would be operable. For example, the spacer rack 10 could have a shape other than rectangular, the slats 24 could be made of a cross-sectional shape other than rectangular, the spacer rack could be used in conjunction with a pallet 12 to support loads other than stacked printing stock, etc. All such modifications, which are within the scope of the claims, are intended to be within the scope and spirit of the present invention.

Claims

I claim:

2. The spacer rack apparatus of Claim 1, wherein the body member has a substantially rectangular shape.

3. The spacer rack apparatus of Claim 1, wherein the apparatus is integrally formed as a single unit.

4. The spacer rack apparatus of Claim 1, wherein the apparatus comprises cardboard.

5. The spacer rack apparatus of Claim 1, wherein the apparatus comprises fiberboard.

6. The spacer rack apparatus of Claim 1, wherein the apparatus comprises plastic.

7. The spacer rack apparatus of Claim 4, wherein the apparatus comprises a plastic foam material.

8. The apparatus of Claim 1, wherein the apparatus is dimensioned to fit on top of a pallet.

9. The apparatus of claim 1, wherein said body member comprises adjacent walls on opposite sides of each of said grooves, wherein each of said adjacent walls is substantially vertically oriented.

10. A method of supplying thin sheets of printable stock to a printing press, comprising the steps of:

11. The method of claim 10, further comprising the steps of

12. The method of claim 10, further comprising a step of disposing of the spacer rack apparatus.

13. The method of claim 10, further comprising a step of reusing the spacer rack apparatus.

14. The method of claim 11, further comprising a step of disposing of the spacer rack apparatus.

15. The method of claim 11, further comprising a step of reusing the spacer rack apparatus.

16. A disposable and reusable spacer rack apparatus for cooperating with a pallet to support a stack of thin sheets thereon, said spacer rack apparatus comprising:

17. The spacer rack apparatus of claim 16, wherein a part of said upper facing is displaced downwardly in selected areas thereof, to define a floor portion at an area of said body member immediately below each of said grooves.