Note: Descriptions are shown in the official language in which they were submitted.
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SUPPORT CRADLE FOR ROLLED COILS AND OTHER CYLINDRICAL OBJECTS
BACKGROUND OF THE INVENTION
The present invention is directed to a cradle unit, or supporting member, for
supporting
and storing coils, such as wound rolls or coils of long lengths of thin flat
material made of steel,
other metal, paper, or the like, which are processed, handled, stored and
transported with the
longitudinal axis of the coil oriented in the horizontal direction. When
stored in their semi-
finished, in-process stage between operations, in their finished state
awaiting shipment, or during
actual shipment and final storage during actual use, these coils are placed in
designated staging
areas by supporting them on the floor, since allowing these coils to rest
directly on the floor or
other flat surface would produce highly-stressed loading at the tangential
contact points. Even
though these coils may be made of metal, they are relatively soft or pliable,
and susceptible to
damage from scratching, denting or surface-marking when they impinge upon
debris on the floor
or on another hard storage surface.
Many locations where coils are stored are on floors that are not flat, tending
to misshape
or deform the coil over time. Coils may also be damaged from flattening or
denting when set
down during handling operations, or from excessive pressure or weight while
sitting in storage
due to single-point tangential and high surface-loading. This situation is
exacerbated when coils
are stacked during storage, which is common in the metals industries.
Therefore, significant
expense is incurred from the lost metal and rework of the damaged coils.
Additionally, stacked
coils, when stored on flat floors, represent a safety hazard from roll out of
the bottom tier of the
stack. This situation is hazardous to personnel, the facilities and the coils
that would be affected
by such a collapse of the stack.
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There have been used a number of various techniques in an attempt to address
the above-
mentioned problems. Some of these techniques include: setting coils on rubber
or fabric belting;
using rubber or polyurethane pads with slight indentations to cradle the coil;
using "V"-shaped
blocks made of polyurethane, plastic, wood or metal; and unitized skids of
plastic, wood or
metal, or other similarly constructed devices to contain or protect the coils.
Polyurethane, rubber and plastic coil-support devices possess the ability to
cushion the
coil during set-down. These devices are typically molded or formed into a
single unit, and do not
provide suitable strength or structural integrity to support stacks of coils
without the use of
additional, independent, and separate support structures. Wood supports are
not resilient or
durable, while metal fabricated supports do not cushion and offer a surface
that has is basically
the same as a bare floor. Unitized fabrications of wood, plastic or steel are
expensive to build, do
not offer the durability and protection of a resilient support, and do not
conform or adapt to
uneven floor conditions.
An example of a prior-art support is disclosed in U.S. Patent No. 4,503,978 -
Smit, et al.,
and discloses a support for rolled coils made of polyethylene. The supports of
this patent do not
generally provide adequate structural support, and, therefore, are typically
supported by U-
shaped steel channels bolted to the floor, or other supporting surfaces, and
are generally not
conformable to a support under-structure.
SUMMARY OF THE INVENTION
It is, therefore, the primary objective of the present invention to provide a
support cradle
for coils, rolls, or other cylindrical objects that provides its own inherent
structural integrity for
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solely supporting a coil thereon, while also conforming to the under-structure
upon which it is
rests, which support cradle may be used to support coils or rolls of different
diameter.
It is, also, the primary objective of the present invention to provide such a
support cradle
that provides its own inherent structural integrity for supporting a coil
thereon, while also
conforming to the under-structure upon which it is secured, which support may
also be
connected to other like-cradles for forming a multi-unit cradle-support for
supporting a series of
coils thereon, while still maintaining its conforming characteristics for
preventing damage to the
coils supported thereon, and for safely stacking of rows of coils thereabove.
In it, also, the primary objective of the present invention to provide a pair
of rails for
fixedly mounting and supporting a plurality of support cradles, where each
support cradle is held
in place by the rails via metal pins protruding or projecting from the bottom
surface of the
support cradle that are received in openings formed the rails, while the rails
themselves are
affixed to the floor, whereby no lateral or longitudinal movement or sliding
of the support
cradles is possible.
In accordance with the invention, the cradle unit for supporting metal coils,
and other
cylindrical objects, consists of two parallel and separate cradle-sections or
saddles made of
polyurethane, or other material, having a hardness range of between 50 Shore A
and 90 Shore D,
which cradle-sections are joined or connected together via a pair of parallel
steel angle-brackets
that provide inherent structural integrity to the cradle unit itself, while
still allowing the saddles
to conform to the shape or level of the underlying support structure, whereby
a plurality of cradle
units may be used for supporting coils in a tiered stack. The single cradle
unit may be used as a
mobile support-device, or may be bolted or otherwise attached to a surface for
a specific location
of the stored product. The cradle unit of the invention may, also, be attached
to the bed of a
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transportation vehicle, such as a truck trailer or rail car, in order to
provide secure, protective
storage and location of the items. In this case, the nature of the resilient
or soft material from
which the cradle unit is made provides shock-absorption qualities for the
transported coil.
The cradle unit generally defines a concave-shaped upper surface, and has a
first main or
central lower concave curvature of a first radius, a pair of middle or
secondary transitional
curvature-sections that connect the first main lower curvature to a pair of
upper, tertiary concave
curvature-sections of a second radius greater than the first radius, so that
coils or rolls of
different diameter may be safely and firmly accommodated.
In a modification of the invention, a multiple-unit version is provided where
a series of
cradle units of the invention are connected together to form one elongated
integral support
structural unit. This modification is a unitized rack that forms a row-storage
arrangement where
the stored coils or objects are stored randomly along the length of the rack,
for securing and
protecting the stored coils or objects, with the coils arranged lengthwise
along the length of the
rack.
In another modification, each cradle unit is provided with outwardly-
projecting oil-
receiving pans or reservoirs for collecting oil or liquid lubricant seeping or
draining out from the
ends of the coil supported thereby. These pans provide for the containment of
the fluid to prevent
contamination of the surrounding environment, and provide for safe, easy
recovery and disposal
of the liquid.
In yet another modification, a plurality of support cradles are loosely
mounted in place to
a pair of rails which, in turn, is affixed to a floor in order to prevent
sliding of the support cradles
while allowing for flexing of the support cradles under full-load conditions.
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BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood with reference to the
accompanying
drawings, wherein:
Figure 1 is an isometric view of the cradle unit for supporting a coil, roll,
or other
cylindrical object in accordance with the invention;
Figure 2 is a top view thereof.
Figure 3 is a side, elevational view thereof;
Figure 4 is an end view thereof;
Figure 5 is an isometric view showing a series of cradle units of Fig. 1 being
used to
support a tiered stack of coils or rolls;
Figure 6 is an isometric view similar to Fig. 5 showing the force vectors
acting on the
coils or rolls and on the series of cradle units supporting the stack of coils
or rolls;
Figure 7 is an isometric view of a modification in which a series of cradle
units of Fig. 1
are provided in one unitary structure for forming a rack for supporting a
series of coils, rolls, or
other cylindrical objects in a row;
Figure 8 is an end view thereof;
Figure 9 is a side elevational view thereof;
Figure 10 is an isometric view showing a series of cradle racks of Fig. 7
being used to
support a plurality of stacked rows of coils or rolls;
Figure 11 is an isometric view of another modification of the cradle unit of
Fig. 1 with
the addition of a pair of end-pans serving as reservoirs for collecting
lubricant draining from
coils or rolls supported or stacked thereon;
Figure 12 is a side elevational view thereof;
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Figure 13 is a top view thereof;
Figure 14 is an end view thereof;
Figure 15 is a side view of yet another modification of the cradle unit where
each the
cradle unit is provided with protruding metal pins for reception in openings
of a pair of rails
affixed to a floor, or the like, by which the cradle unit is retained in place
and prevented from
sliding movement;
Figure 16 is a top view thereof;
Figure 17 is an end view thereof;
Figure 18 is a top plan view of a rail fixable to a floor or other
understructure to a pair of
which rails a cradle unit of Fig. 15 is secured;
Figure 19 is a top plan view of a pair of rails of Fig. 18 affixed to a floor
or other
understructure and shown supporting and securing a plurality of cradle units
of Fig. 15 in a
spaced apart manner via the protruding metal pins of the cradle units received
in openings of the
rails; and
Figure 20 is a side elevational view of Fig. 19.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in greater detail, and to Figs. 1-6 for now,
there is shown
a cradle unit 10 of the invention for supporting a coil, roll, or other large
cylindrical object. The
cradle unit 10 consists of a pair of parallel-arranged, identical end-cradle
sections or saddles 12,
14 preferably made of polyurethane, in the hardness range of between 50 Shore
A and 90 Shore
D. The length of each end-cradle section or saddle 12, 14 depends upon the
size or sizes of the
coils or rolls to be supported. In one example, each end-cradle section is
thirty three inches in
length and three inches in width. Each end-cradle section or saddle 12, 14
defines an upwardly-
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facing concave supporting surface 16, 18 which consists of a first lower or
main portion 16', 18',
respectively, having a first radius R1, and second upper or tertiary end
portions 16", 18" each
having a second radius R2 that is greater than the radius R1. Connecting the
surface-portion 16'
or 18' with the portions 16" or 18" are transitional curvature-portions or
regions 20, 22,
respectively. The values of R1 and R2 will vary depending upon the size of
coils or rolls to be
supported. The value R1 corresponds to the radius of the minimal coil or roll
to be supported by
the cradle 10, while the value R2 corresponds to the radius of the maximal
coil or roll to be
supported by the cradle 10. In the example given above, the first radius R1 is
twenty inches,
while the second radius R2 is thirty six inches, with the height of each end-
cradle section or
saddle increasing from a minimum of one inch at the midpoint or center to a
maximum of five
inches at the extremity or end 24, 26.
With regard to the transitional regions 20, 22, it is noted that the first
lower or main
portion 16', 18' and the second upper or tertiary end portions 16", 18" not
only have different
radii R1 and R2, but, of course, also have different points of centers ptl and
pt2, respectively.,
The shape or curvature of each transition region 20, 22 is formed by
generating a number of
circles of different radii and from a varying center position pt[i] between
the center points ptl
and pt2 in a linear relationship. Using the equation: pt[i] = ptl + (pt2 -
ptl) / (r2 - rl) * abs(rl -
r[i]), where pt[i] is a center point of a transitional circle and r[i] is the
radius of the transitional
circle, connecting the tangents of these generated circles form the curve of
each transition region
20, 22.
The cradle unit 10 also includes a pair of parallel-arranged steel angle-
brackets 30, 32
which provide the inherent structural integrity to the unit. Each angle-
bracket connects
corresponding ends of the two end-cradle sections 12,14, as seen in Fig. 1.
Each angle-bracket
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30, 32 consists of a horizontal section 34 and a vertical section 36, with a
respective end of a
cradle unit being nestled therein. The right-angle brackets are bonded to the
ends of the end-
cradle sections by conventional bonding techniques, whereby a flexible and
adaptable rectilinear-
shaped structure is formed. In the above-mentioned example, the length of each
angle bracket
may be typically thirty-six inches, with the width of each of the horizontal
and vertical sections
typically being three inches, and typically made of 3/16" steel. Each
horizontal section 34 may
be provided with a pair of holes 46 for passing therethrough bolts for
securing the cradle unit 10
to a floor or other under-structure.
Referring to Fig. 5 and 6, it may be seen how a series of cradle units 10 may
be used to
support a tiered vertical stack of rows of coils or rolls 40. The force vector
diagram depicts coils
Cl through C8 stacked on the coil cradle units 10 of the invention. The loads
are calculated as if
the stack continues on to the left of the diagram. Each coil shown has been
assumed to be of a
72" O.D. and a weight W. Because of the stacking, the downward force W splits
into the two
vector forces WL and WR. For purposes of clarity, only coil C2 has been shown
with the forces
labeled. On the middle row, the forces acting on coil C4 are its weight W plus
WR from coil Cl
and WL from coil C2. The resultant force, 2=W, is drawn using vector addition.
The forces acting
on coil C5 are its weight W plus WR from coil C2. The resultant force is drawn
using vector
addition. On the bottom row, the forces acting on coil C6 are its weight W
plus 2= WR from coil
C3 and 2= WL from coil C4. The resultant force, 3=W, is drawn using vector
addition. The forces
acting on coil C7 are its weight W plus 2= WR from coil C4 and WL from coil
C5. The resultant
force is drawn using vector addition. The forces acting on coil C8 are its
weight W plus 2= WR
from coil. The resultant force is drawn using vector addition. On the bottom
row, lines are drawn
from the center of the coils to the edges of the ends 24, 26 of the cradle
units. If the resultant
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force vectors remain in between these lines, the stack will be stable,
assuming that the coils in
the stack are frictionless and not considering inertia. In actual use, the
stack could be stable even
if this limit were somewhat exceeded. Because of the provision of two separate
upper curved
sections of different radii R1 and R2 for each cradle unit, multiple layers of
coils of different
diameter may be more safely stacked, as shown in Figs. 5 and 6.
Referring now to Figs. 7-10, there is a shown a modification in which a series
of cradle
units 10 are provided to form a rack 50 of cradles for supporting a plurality
of individual coils
thereon end-to-end to form a ladder-like structure. The rack 50 consists of a
plurality of cradle
elements 52 similar to the end-cradle sections 12, 14 of the cradle unit 10,
which cradle sections
52 are interconnected together by a pair elongated steel angle-brackets 54, 56
similar to the
angle-brackets 30, 32 of the cradle unit 10 of Fig. 1. The spacing between the
cradle elements 52
is generally less than the spacing between the end-cradle sections or saddles
12, 14 of the cradle
unit 10. Whereas the spacing between the cradle sections 12, 14 in one example
cited above is
thirty inches, the spacing between adjacent cradle elements 52 is 15-1/4
inches, so that, not only
variously-sized rolls or coils of different diameters may be supported and
stored on the rack 50,
but also coils or rolls of different lengths may be supported thereby. In
addition, owing to the
series arrangement of cradle sections 52, the placing of a coil or roll on the
rack 50 may be
achieved at any portion along the length thereof thereby allowing facility of
placement and
storage. A plurality of racks 50 may be employed in parallel formation, as
shown in Fig. 10, in
order to allow for support and storage of multiple, stacked rows of coils or
rolls 40. The spacing
between racks 50 is dependent upon the size of the coils or rolls 40 to be
supported. Each
individual rack 50 is bolted to the floor or under-structure by bolts passing
through the angle
brackets, in the same manner described above with reference to the cradle unit
10. In addition,
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oil pans similar to oil pans described hereinbelow with reference to Figs. 11-
14, may also be
used for collecting oil, or other fluid. It is noted that the individual rolls
or coils are supported
end-to-end, with their longitudinal axes being parallel to the length of the
rack, whereby the rack
50 supports them in the manner that has hithertofore only been done using a
coil pad. Thus, the
rack 50 serves the dual function of acting as cradle supports and as a coil
pad.
Referring now to Figs. 11-14, there is shown another modification 60 of the
cradle unit
in which a pair of oil-collecting pans or reservoirs 62, 64 are provided at
the ends of the
cradle unit in order to collect oil or other lubricant or fluid seeping or
draining out from the ends
of the coil supported thereby. These pans provide for the containment of the
fluid to prevent
contamination of the surrounding environment, and provide for safe, easy
recovery and disposal
of the liquid. Each oil-collection pan 62, 64 is preferably formed integrally
with the respective
cradle section 12, 14, and typically has a width of twelve inches and a length
of two feet. Each
pan 62, 64 is provided with an upstanding lip or rim 62', 64' for containing
the oil. The rest of
the cradle unit 60 is substantially identical to the cradle unit 10.
The cradle of the invention adapts readily and inherently to the contour of
the underlying
support structure or floor, with the spacing between the angle-brackets and
between the saddles
providing a self-adapting unitary structure, so that uneven or contoured
floors will not adversely
affect the support provided by the cradle of the invention. Moreover, the
inherent resiliency of
the material used in the saddles offer shock-absorption characteristics.
While the preferred material for the saddles has been indicated as being
polyurethane,
other, comparable or equivalent material may be used instead, or composites
thereof, as long as
these other materials are within the same hardness range of between 50 Shore A
and 90 Shore
D. Some of these other materials are, for example: nylon; nyrim; polyethylene
of all molecular
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weights (ultra high, high density, medium density, low density, copolymers,
homopolymers);
rubber such as SBR, EPDM, nitrile, Neoprene (polychloroprene), natural,
Hypalon
(chlorosulfonated polyethylene rubber), butyl; granulated and rebonded rubber;
and recycled
plastics; recycled plastic/wood flour or other similarly formulated blends;
polypropylene; vinyl
(PVC).
While specific dimensions have been given hereinabove, it is to be understood
that these
have been given only by way of example. The actual dimensions may vary
depending upon the
lengths and diameters of the coils or rolls intended to be supported.
While the transition regions 20, 22 have been described as having shape or
contour
described hereinabove, it is to be understood that other methods for producing
the shape or
contour thereof may employed, as well other different shapes and curvature.
In a variation of the support cradle, the end-cradle section or saddle 12, 14
defines an
upwardly-facing concave supporting surface 16, 18 which consists of a first
lower or main
portion 16', 18', respectively, having a first radius R1 of about 18 inches,
second upper or
tertiary end portions 16", 18" each having a second radius R2 of about 36
inches, with the height
of each end-cradle section or saddle increasing from a minimum of 1-1/2 inches
at the midpoint
or center to a maximum of 8-1/2 inches at the extremity or end 24, 26.
Referring now to Figs. 15-20, there is shown another modification 68 of the
cradle unit.
This version has especial relevance for the storage of coils, rolls, and the
like, on the floor of a
truck during transportation thereby, although it is intended for use in all
storage environments
and locations, whether mobile or fixedly stationary. In order to take into
account moments and
forces tending to dislodge or displace the support cradles during normal use
and loading, there
are provided at least one pair of longitudinal rails mounted to the floor of
the truck, as shown in
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Figs. 18-20. The pair of rails 70, 72 are spaced apart on the floor or other
understructure by a
distance that accommodates the width of the support cradle unit 68, which
width is defined in
the direction between the saddles 82 of the cradle unit or alternatively by
the length of each
connecting brace 90, 92.
In the preferred embodiment, this spacing is either thirty or thirty-six
inches, as taken
between the outer surfaces 70', 72' of the rails. Each rail 70, 72 is provided
with a first series of
pairs of holes or openings 76, 78 by which screws or bolts permanently affix
the rails a floor.
There are also provided a second series of equally-spaced apart holes or
openings 80 by which
support cradles are connected to the rails. The cradle unit 68 is similar to
the saddle units of the
other embodiments described hereinabove, with the exception of the addition of
a pair of spaced-
apart metal pins 84, 86 formed in each of the cradle sections or saddles 82.
Each metal pin 84, 86
has a projecting or protruding bottom section 84', 86' provided in and
projecting from the
bottom surface 82' of a saddle 82, which projecting sections 84', 86' are
received in respective
openings of the series of the openings 80 of the rails 70, 72. The openings 80
are of a larger
diameter than that of the pins 84, 86 so that the protruding bottom sections
84', 86' are loosely
received in the holes 80 in order to allow a limited degree of movement. This
loose mounting of
the pins in the openings 80 is done because, during normal loading of the
support cradles with
coils, the cradle units experience flexing and bending whereby the distance
between the center
lines of the pins 84, 86 tend to change, This loose fitting accommodates such
flexing and
bending. In the preferred embodiment, each metal pin 84, 86 is approximately 4-
7/16 inches in
length and has a diameter of approximately 7/8 of an inch, with a projecting
portion 84', 86' that
project outwardly from the bottom surface 82' of approximately 7/16 of an
inch. Each metal pin
is mounted in a respective saddle by first drilling a hole, and then inserting
and adhesively
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securing a pin in the hole. In the preferred embodiment, the holes 80 of the
rail elements have a
diameter of approximately 1-1/16 inches, which, given the 7/8 inch diameter of
each metal pin
84, 86, allows an approximately 1/16 of an inch play or movement of the pin in
a hole, which is
more than adequate to allow for the changes in spacing between pins 84 or 86
during flexing and
bending under full-load conditions. As mentioned above, the spacing between
the two fixed rails
70, 72 is equal to the width of the cradle unit 68.
Also in the preferred embodiment, the length of each rail is approximately 239-
7/8 inches
a width of three inches, and a thickness of 1/2 inch. The spacing between
holes 80 is
approximately five inches, center to center. Also in the preferred embodiment,
the spacing
between the pins of one saddle and the spacing between the pins of the other
saddle are
approximately thirty inches, center to center. The width of the cradle unit
may be approximately
30 inches or 36 inches, which is equal to length of each of the parallel-
arranged steel braces 90,
92. It is, also, noted that in this modification, the parallel-arranged steel
braces 90, 92 are not
angle-brackets, as in the other embodiments described above, but are just
straight elements
connecting the pair of saddle supports 82 at portions of the saddle supports
above the bottom
surfaces 82' thereof, so that the projecting pins 84, 86may be used for
mounting the cradle unit
68 in the rails 70, 72, in the manner described hereinabove.
Also, in the preferred embodiment, the radius R1 for cradle unit 68 is
eighteen inches and
the radius R2 is thirty-six inches. The transition region is determined using
the same method
described hereinabove with reference to the embodiment of Fig. 1.
While the pins 82, 84 have been indicated as being metal, it is to be
understood that other,
equivalent materials may be used. In addition, the above-listed dimensions
have been given only
by means of example and are not to be construed to be limiting. Moreover,
while the projecting
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members have been described as pins, other equivalent members may be used
instead, it being
understood that the projecting members are not to be construed to exclude
other equivalent
members or manners for mounting the saddles in the holes of the rail elements
for a limited
degree of movement therein.
While specific embodiments of the invention have been shown and described, it
is to be
understood that numerous changes and modifications may be made therein without
departing
from the scope and spirit of the invention as set forth in the appended
claims.
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