Patent Application
20050152774
As described in Nunes U.S. patent application Ser. Nos. 10/210,462 and 10/345,575, a method and apparatus is disclosed for transporting a group of containers without the need for a conventional pallet.
Containers of merchandise such as produce containers are typically transported in a group, strapped or otherwise secured to a pallet, which is typically made of wood.
As one cost and disadvantage of the shipment of products such as produce or manufactured items from a source of supply to the consumer, the respective pallets tend to make a one-way trip, where they accumulate at receiving sites, often forming a small mountain of pallets. This of course is obviously wasteful and costly.
By the inventions of Mr. Nunes, cited above, a system has been developed in which groups of containers may be handled in a conventional manner of pallet transportation, but the pallets, if present at all, are not transported for the entire journey along with the containers. This reduces the number of pallets required, and the one way flow of pallets from a production area to the customer, so that the customer is not burdened with great quantities of surplus pallets. Thus, a method is provided of transporting a group of containers without transporting the pallet, although the containers may initially rest on a pallet, if desired.
By this method, the prongs of a lifting device may be inserted into first, open grooves defined in a first support surface underneath the group of containers. The prongs are positioned to support all of the containers in the group. The containers are then lifted from the pallets, with the group of containers being transported by means of the lifting device to a transport vehicle.
The prongs of the lifting device then may be inserted into second, open grooves defined typically on the floor of a transport vehicle or other second support surface, to permit the group of containers to rest on the surface. One then withdraws the prongs from the second, open grooves. The containers may then be transported to the new destination.
Following this, the group of containers may be unloaded from the transport vehicle by inserting prongs of a second lifting device into the second, open grooves, and lifting and removing the group of containers from the transport vehicle. Then, optionally, the prongs of the second lifting device, carrying the group of containers, may be inserted into third, open grooves of another pallet, or a shelf, a floor, or other third support surface, to permit the group of containers to rest on the third support surface, followed by withdrawing the prongs of the second lifting device.
Thus, by this technique, efficient transportation of the group of containers from one location to another is provided without also transporting the pallets. A surplus of pallets does not have to accumulate at the new designation. This avoids the need of purchasing or manufacturing a constant supply of pallets at the original location where the containers are assembled into their groups.
The term “lifting device” may comprise any device that carries prongs and is capable of lifting a group of containers by those prongs, such as forklift vehicles, pallet jacks (hand operated and otherwise), overhead lifts, load transfer stations, and other kinds of lift trucks. These devices are modified in accordance with this invention to carry a container lifting member comprising prongs, which prongs are capable of lifting the containers and are capable of fitting into the various open grooves described above.
In accordance with this invention, improvements are provided to the previously described invention of Mr. Nunes. Particularly, improved, grooved surfaces are provided for the use in storing and transporting of groups of containers, while wholly or partially eliminating pallets.
In accordance with this invention, a grooved support surface (such as a floor or shelf surface) is provided. While support surfaces resting on a subfloor will be specifically described, shelf or rack surfaces, pallet surfaces, and the like may be similarly used, as another kind of “subfloor”. A grooved support surface may be defined by a first plurality of support modules held in side-by-side relation together on a subfloor, or elevated on a rack, for example, carried on a shelf or only at their ends by the rack frame. Individual floor modules each comprise an elongated body having at least a pair of flat segments joined at a common side edge and extending transversely to each other. The floor modules together define a plurality of spaced, longitudinally extending grooves.
These grooves are proportioned so that they may be entered by a fork of a lifting device, which typically is a fork on a forklift having four or more prongs, so that the various prongs of the fork are relatively close together, to facilitate the lifting of a stack of boxes having multiple boxes in each layer of the stack, and frequently several layers of boxes in the stack, such as from one layer to six or eight layers of boxes. Thus, closely spaced prongs will tend to have more support and lifting capability for the individual boxes in the stack, without shifting and collapsing of the boxes through spaces between the prongs. For example, as described in the previously cited Nunes patent applications, the boxes may be of a conventional, rectangular shape, and may be positioned in the well-known five-down stack pattern, although other patterns may be used.
Optionally, at least some of the support modules present may have a cross section which is shaped essentially like three sides of a rectangle, i.e., a square U-shape. Optionally, at least some of the modules present may have a cross section shaped essentially like a rectangular S. These support modules may typically be made from extruded aluminum or another metal. They may be held in the desired side-by-side relation by tack welding, adhesives, bolts, or screws such as flathead screws, integrated locking devices, or any other desired and conventional technique.
In some embodiments, at least some of the support modules have ends that are joined to a ramp to facilitate the use of a known dock leveler while allowing the complete filling of a transport vehicle having a grooved floor in accordance with this invention. The ramp allows the withdrawal of the lifting device prongs after loading of the final stack of containers into the vehicle, providing smooth transition for the lifting device (forklift) wheels onto and off of the support modules. Also, the ramp permits advancing of forks carrying container stacks while the forks enter the grooves, without the forklift impacting the ends of the support modules. Such impact could cause bending and distortation of the modules, with sharp, upturned edges that could do damage to containers, and create unsafe, sharp edges for people working in the area. Typically, the ramp comprises a plurality of ramp modules which are held in side-by-side relation on the subfloor in their position abutting against the support modules.
For longer, grooved floors, a second plurality of support modules, held in side-by-side relation, may substantially abut the first plurality of support modules, with the second plurality of support modules being in end-to-end relation with the first plurality of support modules, and with the grooves aligned with each other so that the structure defines a single, integral, grooved floor or other support surface. Additionally, a third plurality of such support modules (and more) may also be added in similar manner, to achieve any desired length, without the individual support modules being inconveniently long for handling. Typically, such support modules may be order of 6 to 10 feet long, although they may be of any length that is convenient and appropriate. For example, their length can range from the length of a pallet to the length of a truck bed or a room.
The grooved support surface of this invention, comprising one or more pluralities of support modules and optionally the ramp described above, may rest on a subfloor which may particularly comprise the floor of a trailer, a large transport container, a railroad car, aircraft, or a boat, the floor of a storage room such as a cold room, a storage rack, or any other desired support surface, such as a shelf, on which containers are to be stored. The support surface provided by the floor modules of this invention may comprise a semi-permanent flooring which may be used to conveniently store stacks of containers and/or transport them, without the need for the owner to have to commit to a permanent modification. The grooved support surface of this invention may be laid down in the trailer of a semi-trailer truck, for example, or any other subfloor, without the owner of the trailer having to consider this a permanent modification. The grooved support surface of this invention can be used for a lengthy period of time, and then it may be removed without great difficulty, if that is desired, to restore the trailer or other enclosure to substantially its original condition.
Preferably, at least most of the support modules present comprise at least one horizontal, flat segment connected at opposite side edges to a pair of vertical, flat segments. The overall cross section of such a structure may be U-shaped, S-shaped, or another shape as desired. In some embodiments, at least some of the vertical segments of different floor modules which are next to each other are spaced from each other, in a manner disclosed below, for better weight support. Also, in some embodiments, at least some of the vertical segments have edges that enter into a groove defined at a horizontal segment of an adjacent support module, examples of which are shown below.
Further in accordance with this invention, improved retention of arrays of elongated modules may be provided by the use of a particular elongated module for placement on a subfloor surface, which comprises an elongated body having a cross-section generally like a squared-S. The body defines a pair of elongated channels having oppositely facing, open mouths. A first interlocking member is connected to the body and projects into one of the elongated channels. A second interlocking member is connected to the body and projects into the other of the elongated channels.
The elongated modules may be locked together in laterally abutting relation, with each of the interlocking members being in connection with an interlocking member of another of the modules, which are in laterally abutting relation therewith. In other words, the module of this invention may be part of an array of laterally abutting modules in which the first interlocking member of a particular module is connected to a second interlocking member of an adjacent module, and the second interlocking member of the particular module is connected to a first interlocking member of another of the modules on another side.
Typically, each of the elongated, open mouthed channels is defined by a bottom wall and a pair of sidewalls of the module. In one embodiment, the first interlocking member may comprise a longitudinally extending bar, connected to the bottom wall of one of the channels at a location spaced from the sidewalls. In the same embodiment, the second interlocking member may be connected to that sidewall which partially defines the elongated channel that is spaced from the first interlocking member, and which defines an outer side of the elongated body.
In some embodiments, the bottom wall of one of the elongated channels defines a hole for a retaining screw, to hold the module onto a subfloor.
In some embodiments, the laterally abutting modules may be longitudinally offset (staggered) from each other, particularly when arrays of modules are placed in end-to-end relation to cover a larger subfloor, and to avoid a linear seam between the end-abutting arrays of laterally abutting modules, and to create interlocking support modules.
In another aspect of this invention, a stack of containers may be placed onto a lifting device such as a forklift, typically having at least four lifting prongs, which are each preferably spaced apart by no more than about 10 inches. This method comprises: placing the stack of containers on a sheet support material which rests on a first support surface. One then advances the lifting device into grooves defined in the first support surface, to place the sheet and the stack of containers onto the prongs of the forklift. The sheets may be made of plywood, corrugated cardboard, plastic, or the like, and may desirably be a low friction material.
The containers may be lifted and transported to a new destination, as desired. Then, the lifting device prongs may be placed into grooves in a second support surface. The lifting device is then retracted, to place the sheet and stack of containers off of the forklift prongs and onto the second support surface.
The support surfaces used herein may be similar in nature to the types of “subfloor” as described above or they may comprise other support surfaces, but with the grooves formed therein.
It should be noted that attempts were previously made to use a sheet of low friction material in this manner, to place stacks of containers on conventional forklifts which have only two prongs. This work proved to be commercially unsuccessful. However, we have found that with the increase in number of lifting prongs, which are preferably spaced apart by no more than about 10 inches, and typically from about 4 to 7 inches, this system works well on grooved floors, without the need for pallets, in handling particularly less stable stacks of smaller containers.
Referring to the drawings:
Referring to
Grooved support surface 10 is defined by a first plurality of support modules 16, as particularly indicated by
The respective support modules 16 are held in side-by-side relation on subfloor 12 (or alternatively carried at their ends by the frame of a rack, or the like). The individual support modules 16 comprise an elongated body as shown and may be made, for example, out of extruded aluminum, or strong plastic, or another material. As shown, each of support modules 16a-16d has at least a pair of flat segments 18, 20 joined at a common side edge 19, and angled to be extending in one dimension transversely to each other, as shown in
The structure as illustrated in
Accordingly, a grooved floor or other support surface 10 of many desired widths may be provided to fit the space allocated to it.
The respective support modules 16 may be secured in their desired, side-by-side relation by tack welding, or any other desired technique. Thus, a grooved floor or other surface may be provided upon which stacks of containers, without a pallet, may be placed and also retrieved.
As shown in
Referring to
By desired arrangement of these respective support modules 42, a grooved support surface having spaced grooves 44 may be provided for the purposes described above. By appropriate use of the differing sized support modules 42a and 42b, the arrangement and width of grooves 44 may be adjusted as desired. The same holds true for the previous embodiment of
As seen in
Thus, the grooved support surfaces of this invention may be used to receive a stack of containers without a pallet, as previously described. Alternatively, a stack of containers may rest upon a flat sheet of material such as corrugated cardboard, thick polyethylene plastic, flat plywood, or the like, which, in turn, is placed upon a respective, grooved support surface such as support surfaces 10 or 40. Such an underlying sheet may be much lower in cost than a pallet, and it can be used to stabilize a stack of smaller packages, which packages may be unitized into a stack by wrapping, strapping, or other techniques. Currently, such unitizing techniques are in commercial use, with the stack resting on a pallet. However, if the packages in the stack are small enough so that stability of the stack is a question, such a flat sheet may be provided under the stack. The increased number of prongs typically used with this invention on the forklift can stabilize such stacks, so that they may be lifted and moved without the use of a pallet, optionally with the use of a support sheet as described above.
Referring to
Furthermore, it can be seen that the respective floor modules 52 and ramp modules 60 may be of differing designs in the manner similar to the previous embodiments, comprising different-width floor modules 52 and ramp modules 60a and 60b, so that the respective grooves 54, 62 may be adjusted in their width as desired.
Thus, the grooved, sloping surface 58 protects the ends 64 of floor modules 52 from being distorted and bent by banging against a forklift that is coming in too low as it delivers packages. Also, damage to packages can be avoided. A similar ramp 56a is shown in
As previously described, a sheet of support material 68 may rest on grooved support surface 50, this sheet of material being made, for example, of plywood, corrugated cardboard, or plastic. The desired load of packages then optionally rests upon sheet 68, on support surface 50. It can be seen that the prongs of a forklift can fit into the grooves 54, 62, to pass under sheet 68, so that sheet 68 and the stack of packages 70 that it carries can be lifted, with sheet 68 providing additional stability to such a stack of packages, when that is needed. For purposes of clarity, stack of packages 70 is represented in
Similarly,
In another embodiment of
Furthermore, module 80 defines a first latch member 100, centrally positioned and extending from bottom wall 88 of channel 84. Module 80 also defines a second latch member 102, carried on the outer sidewall 94 that defines the other channel 86. These latch members 100, 102 engage latch members of laterally adjacent modules, as illustrated by module 80a, which may be of identical structure to module 80, shown in
Also, it can be seen how each wall 90, 90a can press its outer end into a socket 108, which is defined in a laterally adjacent, connected module 80a, 80b.
Referring to the embodiments of
To avoid a single, linear transverse connection seam, the respective modules are slightly longitudinally offset from each other as particularly shown in
Also, as shown, the ends of respective modules 110a may define apertures 116, if desired, to facilitate the flow of air underneath the floor defined by the respective modules 110, 110a, to facilitate cooling of packages resting thereon.
Typically, on each side of a module 117 one finds a groove 112a proportioned in size for the insertion of the prongs of a forklift truck, for the purposes described above.
The forks 146 of forklift truck 140 can be seen to be engaging grooved ramp 148 of a design similar to those previously shown, to enter the grooves 151 of floor modules 150, also of a design similar to that previously shown, resting on a trailer subfloor 152. Thus, product containers 154 that rest on the grooved array of floor modules 150 may be engaged and lifted by forks 146 passing into the grooves 151. Despite the presence of the dock leveler, product may be stacked in trailer 142 to nearly its end, as shown, while still allowing forks 146 to be withdrawn from grooves 151 as forklift truck 140 backs out of trailer 142, without disturbing the last stack of product 154 at the rear of trailer 142.
Accordingly, a system for handling of stacks of containers is provided in which pallets may be partially or completely dispensed with. The grooved floor greatly facilitates the picking up of such containers by a forklift, as does the increase of number of prongs of the forklift to typically four or greater, to provide more sturdy, distributed area weight support under the stack of containers, and thus dispensing with the need for pallets. Thus, such stacks may be stored on shelves or floors without a pallet if desired, and readily picked up for transport, while resting on the grooved support surface of this invention.
Alternatively, packages may rest on pallets, particularly at their destination and their point of origin, but they may be shipped in a palletless manner. Also, particularly for stacks of smaller containers with less stability, a support sheet may be placed underneath the stack to facilitate stability without the need for a pallet. A pallet is defined as a rigid structure defining grooves or recesses to receive forklift prongs, and thus having more depth than a support sheet.
The above has been offered for illustrative purposes only, and is not intended to limit the scope of the invention of this application, which is as defined in the claims below.
