Patent Grant
9422085
Not Applicable.
Not Applicable.
The present invention relates to the field of shipping, and more specifically, the field of packing freight for shipping.
The shipping industry is a multi-billion-dollar industry. Almost every country in the world exports and imports goods to other countries. Additionally, within each country goods are shipped from one part of a country to another. In many cases, goods are shipped in shipping containers that are standardized in size. Containerization for transport has spurred the use of pallets.
A pallet, sometimes called a skid, is a flat transport structure that supports goods in a stable fashion while being lifted by a forklift, pallet jack, front loader, jack, or other jacking or lifting device. Many pallets are wooden, however, pallets may also be made from plastic, metal, paper and recycled papers. Pallets are used to load goods in shipping containers because the shipping containers have the smooth, level surfaces needed for easy pallet movement. Most pallets can easily carry a load of 1,000 kg (2,205 lb). Today, over half a billion pallets are made each year and about two billion pallets are in use across the United States alone. Businesses using standard pallets for loading and unloading can have much lower costs for handling and storage, with faster material movement than businesses that do not.
In operation, goods, freight or other smaller containers are often placed on a pallet then secured with strapping, stretch wrap or shrink wrap. After securing the freight or goods to the pallet, a loading device, such as a jack or front loader, loads or moves the loaded pallet into a shipping container for shipping.
However, the use of existing pallets has its limitations. One of the biggest limitations is that it is the use of existing pallets creates a large amount of under or unutilized space within a shipping or movable container. Typically, the inside of a shipping container has a height that is much higher than a height of goods stacked and secured on a pallet. As a result, when a pallet is loaded, by using a forklift, jack etc., into a shipping container, the space between the top of the inside of the shipping container and the top of the freight loaded on the pallets is empty and not used. As a result, when using existing pallets movable containers or shipping containers are transported with a significant amount of the upper portion of the container underutilized or not filled with goods. Due to such inefficiencies, transportation and fuel costs are increased.
As a result, there exists a need for improvements over the prior art and more particularly for a more efficient way storing goods in movable containers to better utilize the space of such shipping or movable containers.
A system for stacking freight within a shipping container is disclosed. This Summary is provided to introduce a selection of disclosed concepts in a simplified form that are further described below in the Detailed Description including the drawings provided. This Summary is not intended to identify key features or essential features of the claimed subject matter. Nor is this Summary intended to be used to limit the claimed subject matter's scope.
In one embodiment, a system for stacking freight within a shipping container is disclosed. The system comprises a first pallet configured to be removably affixed below and have vertical relief from a second pallet when the system is in a fully assembled state. The first pallet includes a first pallet top planar part having a plurality of orifices proximate to a perimeter of the first pallet top planar part. The first pallet also includes a first pallet bottom planar part having a plurality of apertures. The apertures are configured to allow a set of wheels of a lifting device to contact ground. A plurality of blocks is affixed between the first pallet top and bottom planar parts. Each block has a cutout adapted to correspond with the orifices of the first pallet top planar part, and wherein the plurality of blocks provide vertical relief between the first pallet top and bottom planar parts so that the forks of a lifting device can be positioned between the top and bottom planar parts of the first pallet.
The system also includes a second pallet configured to be removably affixed on top of and have vertical relief from the first pallet. The second pallet comprises a second pallet top planar part. The second pallet bottom planar part having a plurality of orifices proximate to a perimeter of the second pallet bottom planar part, and further comprising a plurality of apertures inward from the plurality of orifices. The apertures are configured to allow a set of wheels of a lifting device to contact ground. A plurality of blocks is affixed between the second pallet top and bottom planar parts. Each block has a cutout adapted to correspond with the orifices of the second pallet bottom planar part, and wherein the plurality of blocks provide vertical relief between the second pallet top and bottom planar parts of the second pallet such that the forks of a lifting device and be positioned between the top and bottom planar parts of the second pallet.
The system also includes a plurality of first vertical support members, wherein each first vertical support member comprises an elongated body having a first end opposing a second end, wherein the first end of each first vertical support member is configured to be received by the orifices and corresponding cutouts of the first pallet, wherein the second end of each first vertical support member is configured to be received by the orifices and corresponding cutouts of the second pallet, and wherein the first vertical support members are configured to be vertically arranged to support the second pallet on top of the first pallet and provide vertical relief between the first and second pallets when the movable modular system is in the fully assembled state. The system also includes a plurality of crossing support members, each crossing member comprising an elongated body having a first end opposing a second end and wherein each crossing member is adapted to span from proximate to the first end of a vertical support member to proximate to the second end of an adjacent vertical support member when the system is in the fully assembled state. A plurality of fasteners are used to removably attach the ends of the crossing support members to the first support members when the system is in the fully assembled state.
Additional aspects of the disclosed embodiment will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the disclosed embodiments. The aspects of the disclosed embodiments will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosed embodiments, as claimed.
The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the disclosed embodiments. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
The following detailed description refers to the accompanying drawings. Whenever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While disclosed embodiments may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting reordering, or adding additional stages or components to the disclosed methods and devices. Accordingly, the following detailed description does not limit the disclosed embodiments. Instead, the proper scope of the disclosed embodiments is defined by the appended claims.
The disclosed embodiments improve upon the problems with the prior art by providing a movable modular system for stacking freight within a shipping container. The present embodiments improve over the prior art by providing a system that allows multiple pallets to the stacked on top of one of another within a shipping container. The present embodiments also improve over the prior art by providing a system that can be disassembled into smaller components and easily assembled. The present embodiments also improves over the prior art by providing a system that can be utilized with standardized shipping or moving containers as well as standardized lifting devices, such as fork lifts, front loaders, jacks, etc. The present embodiments allow significantly more utilization of shipping containers thereby decreasing shipping costs to consumers.
Referring now to the Figures,
In
Referring now to
In one embodiment the support members may also include a plurality of crossing support members 420 to provide additional support to the second pallet on top of the first pallet when the system is in the fully assembled state. Each crossing member may comprise an elongated body 425 having a first end 430 opposing a second end 435. Each crossing member is adapted to span from proximate to the first end 410 of a first vertical support member to proximate to the second end 415 of an adjacent vertical support member when the system is in the fully assembled state. A plurality of fasteners 456 are used to removably attach the ends of the crossing support members to the first support members. In one embodiment, when in the fully assembled state each side of the system comprises two crossing members affixed by fasteners to adjacent first vertical support members. The crossing members may form an x-shape spanning adjacent first vertical support members. Additionally, the crossing members may be removably affixed to each other at a midpoint 505 of each crossing member by fasteners.
In one embodiment, the support members may also include a plurality of second vertical support members 440 to provide additional support to the second pallet on top of the first pallet when the system is in the fully assembled state. Each second vertical support member may comprise an elongated bar shape body 445 having a first end 450 opposing a second end 455. Each second vertical support member is configured to be vertically arranged at a midpoint between adjacent first vertical support members when the system is in the fully assembled state. In one embodiment, four second vertical support members may be used when the system is in the fully assembled state. The first end 450 of each second vertical support member is configured to be received by an orifice 210 and corresponding cutout 235 of the first pallet. In the present embodiment, the cross-sectional diameter of the second vertical support member is smaller than the diameter of the first vertical support member. However, it should be noted that various sizes of diameters of the support members can be used and the second vertical support member may have the same or larger diameter as the first vertical support member. The sizes of the orifices and corresponding cutouts of the first pallet will be adapted to receive the various sizes of the cross-sectional diameters of the first ends of both the first and second vertical support members. Additionally, the sizes of the orifices and corresponding cutouts of the first and second pallets will be adapted to receive the various sizes of the cross-sectional diameters of both the first and second vertical support members.
In one embodiment, the second end of each second vertical support member 450 is configured to be received by a capping member 460, which capping member is adapted to abut the downward facing surface of the bottom planar part of the second pallet in order to provide additional support and prevent movement of the system. Each capping member comprises a receiving part 465 configured to receive the second end of the second vertical support member. In the present embodiment, the receiving parts of the capping member comprise a body defining a cylindrical shaped cavity adapted to receive the cylindrical shape of the second vertical support member. However, other shapes for receiving part of the capping member can also be used. The capping member further comprises a planar part 470 adapted to abut a downward facing surface of the second pallet bottom planar part when the system is in the fully assembled state. When in the fully assembled state, the capping member provide additional support and prevents the movement of system when forces, other than downward forces, act on the system.
Additionally, when in the fully assembled state, the second vertical support members may be removably attached proximate to the midpoint 505 of the crossing members by fasteners to provide additional support and stability.
In one embodiment, in a fully assembled state, the system includes the second pallet 150 positioned on top the first pallet 125, wherein the support member provide vertical relief and support the second pallet. The support members include four first vertical members 175. Each first vertical support member is vertically arranged proximate to a corner of the system between the top and bottom pallets. The first end of each first vertical member is received by orifices and corresponding cutouts in the first pallet and the second end is received by the orifices and corresponding cutouts in the second pallet. In one embodiment, the system also includes four second vertical support members 440, each second vertical support member is vertically arranged between two adjacent first vertical members. The first end of the second vertical support member is received by orifices and corresponding cutouts in the first pallet and wherein the second end of each second vertical support member is received by a capping member 460. The four capping members used with the system each have a receiving part or section received by the second ends of the second vertical support members, and a planar part having an upward facing surface that is configured to abut the downward facing surface of the second pallet bottom planar part. In one embodiment, eight crossing members 420 are used when the system is in a fully assembled state. Two crossing members on each side of the system form an x-shape spanning adjacent first vertical support members. Each pair of crossing members are removably affixed to each other at the midpoint of each crossing member. Each crossing member may also be affixed to the midpoint of the body of each second vertical support member by fasteners. Additionally, each end of each crossing member may be affixed to an end of the first vertical support members by fasteners.
In operation, freight may be positioned on the upward facing surface of the top planar section of the first pallet inward from the plurality of 210 orifices. Worth noting is that the freight must be positioned in an area inward from the orifices 210 so as to allow the first ends of the support members (first vertical support member 175, second vertical support member 440) to be positioned into the orifices and corresponding cutouts of the first pallet. The freight may then be shrink-wrapped or secured for shipment. Such shrink wrapping or securing for shipment is well known to those skilled in the art. Next, the freight may be secured using straps or other means to the first pallet. In one embodiment, the first pallet may include features for allowing straps to be secured onto the first pallet to assist in securing freight. Such features may include orifices, apertures, hooks, knobs, etc and are well known to those skilled in the art. Additionally, other embodiments may also be used and are within the spirit and scope of the present invention. Next a lifting device can be used to move (as explained above) the first pallet with freight into a shipping container.
Next, freight may be positioned on top of the upward facing surface of the top planar part of the second pallet. The freight may then be shrink-wrapped or secured for shipment. Such shrink wrapping or securing for shipment is well known to those skilled in the art. Next, the freight may be secured using straps or other means to the second pallet. In one embodiment, the second pallet may include features for allowing straps to be secured onto the second pallet to assist in securing freight. Such features may include orifices, apertures, hooks, knobs, etc and are well known to those skilled in the art. Additionally, other embodiments may also be used and are within the spirit and scope of the present invention.
Next, the first ends of the first and second vertical support members can easily and quickly be positioned into the orifices and corresponding cutouts of the first pallet. Next, the crossing members may be affixed to the first and second vertical support members. Next, the capping members may be secured on top of the second end of the second vertical support members. Next, a lifting device can use its forks so that the second pallet may be positioned on top of the first pallet and support members so that the second ends of the first vertical supports members are received by the orifices 250 and corresponding cutouts 605 of the second pallet and the planar part of the capping members abuts the downward surface of the second pallet bottom planar part.
The support members, including the first vertical support member, second vertical support member, capping member and crossing members may be affixed to each other ahead of time to decrease the amount of time it takes to assemble the system.
In other embodiments, (further explained below and illustrated in
In other embodiments, additional pallets may be used (not shown). For example, a third pallet may be used in order to better utilize space if needed. In such an embodiment, a plurality of orifices proximate to a perimeter of the second pallet top planar part is needed. Additionally, each of the plurality of blocks 255 affixed between the second pallet top and bottom planar parts have a second cutout 610 to correspond with the orifices (not shown) of the second pallet top planar part as illustrated in
The third pallet (not shown) can be configured to be removably affixed on top of and have vertical relief from the first and second pallets. Similar to the second pallet, the third pallet comprises a third pallet top planar part and a bottom planar part separated by blocks. The third pallet bottom planar part has a plurality of orifices proximate to a perimeter of the third pallet bottom planar part. The third pallet bottom planar part further comprises a plurality of apertures inward from the plurality of orifices. The apertures are configured to allow a set of wheels of a lifting device to contact ground so that the third pallet can be moved. Similar to other pallets, the plurality of blocks affixed between the third pallet top and bottom planar parts each have a cutout adapted to correspond with the orifices of the third pallet bottom planar part, and wherein the plurality of blocks provide vertical relief between the third pallet top and bottom planar parts so that the forks of a lifting device can be positioned between the top and bottom planar parts of the third pallet.
When a third pallet is used with the system, a plurality of supplemental first vertical support members are also needed. Like the first vertical support member, each supplemental first vertical support member comprises an elongated body having a first end opposing a second end. The first end of the supplemental first vertical support members are configured to be received by the orifices and corresponding second cutouts 610 of the second pallet (as illustrated in
In one embodiment, the system may comprise a block proximate to a center point of the first pallet. A fifth second vertical support member (not shown) having a first end opposing a second end may be configured to be vertically arranged between the first and second pallets when in the fully assembled state. Like the other second vertical supports, the fifth vertical support supports the second pallet on top of the first pallet and provides vertical relief between the first and second pallets when the system is in a fully assembled state. Similar to other embodiments, the first end of the fifth second vertical support member may be configured to be received by the cutout of the block 705 proximate to the center point of the first pallet. The second end of the fifth second vertical support member may be configured to be received by a fifth capping member (not shown). Similar to the other capping members, the fifth capping member may comprise a receiving part configured to be received by the second end of the fifth second vertical support member. The capping member further comprises a planar part adapted to abut the downward facing surface of the second pallet bottom planar part when the system is in the fully assembled state.
As illustrated in
It should be noted that
A plurality of fasteners to removably may attach the ends of the supplemental crossing support members to adjacent supplemental first support members. Supplemental second vertical supports members and supplemental capping members may also be used when a third pallet is used. Furthermore, additional pallets may also be used in a similar fashion as to how the first second and third pallets are used.
Various types of fasteners may be used. Fasteners may include bolts, nuts, wing nuts, bolts having apertures, pins. Such fasteners for securing support members is well known to those skilled in the art in various combinations not specifically mentioned herein may be used and are within the spirit and scope of the invention. Additionally, various combinations of support members may be pre-coupled and affixed to each other to provide easy assembly of the system. For example, in one embodiment, a pair of crossing members forming an x may be affixed to a second vertical support member and adjacent first vertical support members to decrease the amount of time required for assembly of the system.
The pallets can be sized to provide maximum utilization of the space within a shipping container. The pallets can be made from any material having properties able to support a load. Such materials include metal, wood, plastic, corrugated paper, titanium, aluminum, or any combination thereof.
The plurality of support members, which includes the first vertical support members 175, crossing support members 420, second vertical support members 440, supplemental first vertical support members, supplemental vertical support members, supplemental crossing members, capping members and supplemental capping members may comprise material having properties able to support a load. Such materials include metal, wood, plastic, corrugated paper, titanium, aluminum, or any combination thereof. Additionally, the plurality of support members, including the first vertical support members and second vertical support members can have adjustable lengths so as to increase the dimension of vertical relief for space between the first and second pallets when the system is in the fully assembled state. In one embodiment, the first and second vertical support members can have a telescoping body for adjusting the length. Such telescoping bodies and adjusting mechanisms are well known to those skilled in the arts and various other embodiments of adjusting the length of the support members so as to increase the dimension of the space or vertical relief between the first and second pallets are contemplated and are within the spirit and scope of the invention.
Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.
This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 62/004,729 filed May 29, 2014 and the subject matter of which is incorporated herein by reference.
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