Patent Application
20240017881
Shipping cost can be based on size and weight. The size can be determined by the footprint in the truck. Large items, such as doors, are often laid flat during shipping which increases the size and thus the cost. Sometimes, special crates are used that are expensive to fabricate. In addition, the wood from the crate is often wasted because the crates are not re-usable because it can be too costly to return ship an empty crate. The development of improved shipping containers and methods is an ongoing endeavor.
Features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention; and, wherein:
Reference will now be made to the exemplary embodiments illustrated, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended.
Before invention embodiments are disclosed and described, it is to be understood that no limitation to the particular structures, process steps, or materials disclosed herein is intended, but also includes equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular examples only and is not intended to be limiting. The same reference numerals in different drawings represent the same element. Numbers provided in flow charts and processes are provided for clarity in illustrating steps and operations and do not necessarily indicate a particular order or sequence. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.
An initial overview of the inventive concepts are provided below and then specific examples are described in further detail later. This initial summary is intended to aid readers in understanding the examples more quickly, but is not intended to identify key features or essential features of the examples, nor is it intended to limit the scope of the claimed subject matter.
The invention provides a kit with a re-usable frame of upright braces that can be secured to an existing pallet to allow large cargo, such as doors, to be placed upright on the pallet, reducing the shipping footprint and shipping costs. The frame can be removed from the pallet and shipped back for re-use with minimal expense. In addition, the entire kit or frame can be packaged inside the structure of the pallet for return.
The pallet can be a standard wood pallet. The pallet can have a standard size, such as 48″×48″; 48″×40″; 42″×42″; etc. The pallet can also have a standard height or thickness, such as 4¾″ or 5¾″. Thus, the pallet can have a width and a length both greater than a height. The dimensions can be approximate. For example, a 48″ pallet may actually be 47¼″. In one aspect, the pallet can have a wood construction with three stringers or stringer boards, six top deck boards, and three to five bottom deck boards. In one aspect, the stringer boards can have cutout notches. The pallet can be a 2-way entry pallet where a forklift can lift the pallet from only two sides, or a partial 4-way pallet where a forklift can lift the pallet from all four sides, and a pallet jack from two sides.
The frame or braces can include a set (such as 4) of corner brackets that can fit over the corners of the pallet. The corner brackets can have top and bottom plates, and two contiguous side walls leaving two contiguous sides open to receive the corner of the pallet into an interior pocket.
In one aspect, the top plate can have an aperture. A retaining pin can extend through the aperture and engage the pallet to retain the corner bracket on the pallet. For example, the retaining pin can engage a side of the top deck board opposite an outer side of the corner bracket.
A ring can be carried by the corner bracket. The ring can be secured to the corner bracket.
In another aspect, the top plate can have a threaded aperture, such as a threaded nut welded to the top. A threaded eye-bolt can be threaded into the threaded aperture to secure the eye-bolt to the bracket. The eye-bolt can also extend through the top plate and into the pocket to act as a set screw by engaging a top of the pallet, thus securing the corner bracket to the corner of the pallet. The eye-bolt can provide the ring.
At least some of the corner brackets can have a post extending upward from the corner bracket. For example, there can be two back brackets with posts. Atop rail can extend between two proximal posts. The top rail can have fingers that can insert into open top ends of the posts. The rail can telescope and be secured with a set screw. Similarly, the posts can telescope. The ends of the top rail or the posts can have eyelets.
The rings and the eyelets can receive a cable or strap. The eye-bolts can have two purposes. First, the eye-bolts can be a place to attach a cable or strap. Second, the eye-bolts can screw into the pallet to secure the bracket to the pallet.
In one aspect, a cable or strap can extend between proximal front and back brackets. For example, a cable or strap can extend from a front bracket to the top rail of the back bracket. In one aspect, there can be a single cable or strap extending from a first ring of a first corner bracket to a first eyelet of back bracket, to a second eyelet of the back bracket, and to a second ring of a second corner bracket. In another aspect, a pair of cables can be on opposite sides of the pallet. The cables can be tightened with a turnbuckle. As another example, a strap can extend from the front bracket to the top rail of the back bracket. The strap can have a ratchet to tighten the strap.
In one aspect, both the rear length and height are adjustable, as well as the length of the cable or strap, for depth.
The brackets can be added to an existing pallet to form a crate to receive larger upright cargo, such as doors, between the cables and against the top rail. The brackets can be removed from the pallet after shipping and re-used by shipping the brackets back. In one aspect, the brackets, posts, bars and cable/strap can weigh around 22 Lbs. Thus, freight return can be reasonably priced. In addition, the brackets can be located in the structure of the pallets, i.e. under the top of the pallet, for return shipping.
The frame and the brackets can have different configurations for other shipping items. The configuration can be one-sided, two-sided or four sided. The brackets can also have a center column configuration coupling two pallets together. The brackets can have vertical channels to receive panels to form enclosed sides. The brackets can also be interconnected. The brackets can have two opposite pockets to joint two standard 4-foot pallets together to form an 8-foot pallet. Thus, the pallets can be sold back to recoup at least part of the cost of the pallets. Shipping pallets back to the distributor can be much more than the cost of the pallet itself.
In one aspect, the rear bar and riser can be formed of 16-gauge tube. In another aspect, the rear bar and rise alone cannot handle the weight of the cargo leaning against them. The cable or strap connect to the front and rear of the pallet can distribute the weight on to the corner brackets, making the crate extremely strong but light weight.
In another aspect, the kit, and the brackets, posts, rails and cable/strap can be broken down to a size or length not exceeding 48″. Thus, one or multiple kits can be returned to the shipper on a single 4-foot square pallet, reducing the cost of return shipping.
Referring to
The system 10 and the kit 18 can comprise a frame 14 removably coupled to the pallet 22. The frame 14 can extend above the pallet 22 to form a crate 50 to receive cargo 26 (
The frame 14 can comprise a plurality of corner brackets 54a-d that can be positioned at each corner 58a-d (
In one aspect, each top plate 70 can have an aperture 90. In another aspect, each top plate 70 can have a threaded aperture 90. In one aspect, the top plate 70 can have an aperture 90 with a threaded nut 94 welded over the aperture.
In one aspect, a retaining pin 96 can extend through the aperture 90 and engage the pallet 22 to retain the corner bracket 54 on the pallet 22. For example, the retaining pin 96 can engage a side and inside edge of the upper slat 34 opposite an outer side (such as wall 78b) of the corner bracket 22. In addition, the retaining pin 96 can engage a side an inside edge of the lateral outer side 30 opposite an outer side (such as wall 78a) of the corner bracket 22. The pin 96 can have an enlarged head abutting to the top plate 70 when inserted.
In another aspect, referring to
In one aspect, referring again to
In another aspect, referring to
The frame 14 can also comprise posts 126 carried by and extending from the corner brackets. In one aspect, a pair of posts 126a-b can carried by a pair of proximate corner brackets 54a-b. In another aspect, posts 12a-d can extend from all four corner brackets 54a-d, as described herein and shown in
A top rail or bar 130 can be carried by and can extend between a pair of proximal posts 126a-b. In one aspect, the top rail or bar 130 can have fingers 134 that insert into open top ends 138 of the pair of posts 126a-b. In another aspect, the fingers 134 can be elongated and the top rail or bar 130 can be selectively elevated with respect to the posts 126a-b so that the top rail or bar 130, and thus the posts 126a-b, have a selective height to match the cargo 26. Thus, the posts 126a-b can have a pair of telescoping sections 142. In another aspect, the top rail or bar 130 can have a pair of telescoping sections 146. Thus, the length of the top rail or bar 130 can be selected to match the length of the pallet 22.
In one aspect, the ends of the top rail or bar 130 can have hooks or loops, such as eyelets 150. In another aspect the tops of the posts 126a-b can have hooks or loops, such as eyelets 150. The frame 14 can have at least one cable or strap 154 that can extend between the eyelets 150 of the top rail or bar 130 or the posts 126a-b, and the rings 110a or eye-bolts 110b of opposite corner brackets 54c-d. For example, a single cable or strap 154 can extend diagonally through the eyelets 150 and the rings 110a or eye-bolts 110b. As another example, a pair of cables 154 can be positioned on opposite sides of the pallet 22 and can extend diagonally from the eyelets 150 of the top rail or bar 130 to the eye-bolts 110 of the proximal and opposite corner brackets 54c-d. In one aspect, each cable 154 can have a turnbuckle 158 to tighten the cable 154. In another aspect, each strap can have a ratchet to tighten the cable 154.
The frame 14, and the corner brackets 54a-d, and the posts 126a-b and top rails 130, can have multiple configurations. In one aspect, as shown in
Referring to
Referring to
Referring to
In one aspect, the pair of joiners 166a-b can have a pair of posts 126a-b carried by and extending from the pair of joiners 166a-b. Each post 126a-b can extend upward from the respective joiner 166a-b. A top rail or bar 130 can be carried by and can extend between a pair of posts 126a-b.
In another aspect, the frame can be a center column frame 14d used with a pair of pallets 22a-b. The pallets 22a-b can be joined by the joiners 166. The frame 14d can comprise: four corner brackets 54a-d at each corner of the pallets 22a-b; the pair of joiners 166a-b; a pair of posts 126a-b carried by the pair of joiners 166a-b; a top rail or bar 130 carried by and extending between the pair of posts 126a-b; and four cables 154 extending diagonally from the eyelets 150 of the top rail or bar 130 to the eye-bolts 110 of the four corner brackets 54a-d. Thus, cargo 26 can be stacked on both pallets 22a-b and leaned against the top rail or bar 130.
As described herein, the frame 14a-d can have an expanded use configuration with the corner brackets 54a-d mounted to the corners of the pallet 22 and configured to receive cargo 26 therein, as shown in
Referring to
Referring to
As used in this specification and the appended claims, the singular forms (“a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a layer” includes a plurality of such layers.
In this disclosure, “comprises,” “comprising,” “containing” and “having” and the like can have the meaning ascribed to them in U.S. Patent law and can mean “includes,” “including,” and the like, and are generally interpreted to be open ended terms. The terms “consisting of” or “consists of” are closed terms, and include only the components, structures, steps, or the like specifically listed in conjunction with such terms, as well as that which is in accordance with U.S. Patent law. “Consisting essentially of” or “consists essentially of” have the meaning generally ascribed to them by U.S. Patent law. In particular, such terms are generally closed terms, with the exception of allowing inclusion of additional items, materials, components, steps, or elements, that do not materially affect the basic and novel characteristics or function of the item(s) used in connection therewith. For example, trace elements present in a composition, but not affecting the composition's nature or characteristics would be permissible if present under the “consisting essentially of” language, even though not expressly recited in a list of items following such terminology. When using an open ended term in the specification, like “comprising” or “including,” it is understood that direct support should be afforded also to “consisting essentially of” language as well as “consisting of” language as if stated explicitly and vice versa.
The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Similarly, if a method is described herein as comprising a series of steps, the order of such steps as presented herein is not necessarily the only order in which such steps may be performed, and certain of the stated steps may possibly be omitted and/or certain other steps not described herein may possibly be added to the method.
The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.
The term “coupled,” as used herein, is defined as directly or indirectly connected in an electrical or nonelectrical manner. Objects described herein as being “adjacent to” each other may be in physical contact with each other, in close proximity to each other, or in the same general region or area as each other, as appropriate for the context in which the phrase is used. Occurrences of the phrase “in one embodiment,” or “in one aspect,” herein do not necessarily all refer to the same embodiment or aspect.
As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, a composition that is “substantially free of” particles would either completely lack particles, or so nearly completely lack particles that the effect would be the same as if it completely lacked particles. In other words, a composition that is “substantially free of” an ingredient or element may still actually contain such item as long as there is no measurable effect thereof.
As used herein, “adjacent” refers to the proximity of two structures or elements. Particularly, elements that are identified as being “adjacent” may be either abutting or connected. Such elements may also be near or close to each other without necessarily contacting each other. The exact degree of proximity may in some cases depend on the specific context.
As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint. It is understood that express support is intended for exact numerical values in this specification, even when the term “about” is used in connection therewith.
The terms “interference fit” and “friction fit” and “press-fit” are terms of art used interchangeably herein to refer to deliberately causing, increasing and/or using friction to deliberately resist movement. An interference fit or friction fit is different than and great than the existence of friction. While friction may exist between any two surfaces, is often desirable to do all one can to reduce this friction. An interference fit or friction fit can be distinguished from naturally occurring friction by being actually deliberately caused and increased. An interference fit can be created by dimensioning engaging parts so that their surfaces tightly bear against one another. A friction fit can be created by surface roughness that is rougher.
It is to be understood that the examples set forth herein are not limited to the particular structures, process steps, or materials disclosed, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular examples only and is not intended to be limiting.
Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more examples. In the description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of the technology being described. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
While the foregoing examples are illustrative of the principles of the invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts described herein. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below.
Priority is claimed to U.S. Provisional Patent Application Ser. No. 63/388,413, filed Jul. 12, 2022, which hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63388413 | Jul 2022 | US |
