Note: Descriptions are shown in the official language in which they were submitted.
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SHIPPING CASE AND CONNECTING DEVICE FOR USE WITH CASE
This invention relates to connecting devices for use in shipping cases
and also relates to shipping cases for transporting and storing of products,
including cases adapted to be collapsed or disassembled when not in use and
subsequently restored to full size and shape when required for shipping
purposes.
A variety of cases have been developed for shipping components and
parts, including cases which are simply disposed of after use and cases which
can be collapsed or disassembled after the components or parts have been
removed therefrom so that the cases can be shipped back to the
manufacturer for reuse. The prior art reusable or collapsible shipping
containers generally comprise a plurality of panels including a base panel,
side panels and a top panel or cover and these can be coupled to one
another with the aid of various forms of fasteners or attaching devices. In
some cases, the fasteners comprise hinge connectors which can both connect
adjacent panel edges together and also permit adjacent panel members to be
pivoted relative to one another either to reconstruct the container or to
collapse the container.
Shipping containers made of cardboard and wooden pallets are also
well known in the shipping industry. A disadvantage of cardboard containers
is that they can become damaged easily during shipping. With the use of
wooden shipping pallets, efficient packing of the pallets and the goods or
boxes arranged thereon can be difficult, if not impossible. Also, wooden
pallets generally do not have reliable means for securing the components,
parts or boxes on the pallet or any means for protecting the parts,
components or boxes from damage or tampering during loading, unloading
or shipping.
US Patent No. 3,990,599 issued November 9, 1976 to Mary Rowlex
describes a knock-down, reusable shipping container that includes completely
separable top, base and sidewalls and fasteners for securely fastening
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adjoining corners of the walls. Spring clip fasteners cooperate with
reinforcing plates on the container walls to provide corner connections.
US Patent No. 6,299,011 issued October 9, 2001 describes a
stackable, knock-down box for transportation of produce, this box comprising
a base pallet and six sidewall panels which are hinged together to define a
sidewall enclosure which can be folded. Base clip arrangements are provided
for releasably holding the sidewall enclosure to the base pallet.
Recent US Patent No. 6,598,756 describes a knock-down stillage box
that includes a base pallet assembly and four sidewalls. In the assembled
state, the box contains stillage components for storing cargo such as panels
inside the box. Lower sidewall panels are connected to the base panel by
means of L-shaped clips. The stillage components and the clips for a box can
be housed within a subvolume of the box when the knock-down box is
shipped.
Despite these various known shipping containers and boxes, there
remains the need for an improved shipping case for transporting and storing
of products which can be collapsed or disassembled when not in use and
subsequently restored to its full size and shape when required for shipping
purposes and which has an efficient connecting arrangement which can be
used to secure parts or components in the shipping case in order to prevent
or reduce damage to these parts or components during transport of the case.
There is also a need for an improved connecting device for use in a shipping
container and in particular such a device which can be made at a low cost
and which can easily be used by shippers a number of times.
According to one embodiment of the present disclosure, a connecting
device for attachment to an inside surface of a container wall in order to
secure one or more products inside of the container includes a plate member
adapted to engage the inside surface and having fastener holes formed
therein for attaching a product supporting member to said plate member by
means of fasteners. The device further includes a clip attached to the plate
member and extending over a rear surface of the plate member. During use
of the connecting device, the clip can be inserted into a recess or hole
formed
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in the inside surface and can then be moved to engage a section of the
container wall having an exposed planar surface which engages the plate
member. In this manner, the connecting device can be detachably attached
to the container wall.
According to an exemplary embodiment of the aforementioned
connecting device, the clip is integrally attached to the plate member and is
located centrally relative to the plate member. The fastener holes are located
on opposite sides of the clip.
According to another embodiment of the present disclosure, a
connecting device for use in a shipping case having a bottom and walls
adapted to extend upwardly from the bottom and about a peripheral edge of
the bottom, includes a rigid plate member having two opposite ends and two
opposite side edges extending between the opposite ends. A series of
fastener holes are formed in this plate member. The device also includes an
integral clip attached to the plate member, projecting from a rear surface of
the plate member, and extending along the rear surface in a longitudinal
direction parallel to the side edges. The clip is sized to be insertable into
a
connecting hole formed in the planar wall section of at least one of the
walls.
The connecting device can be detachably connected to the planar section by
first inserting the clip into the connecting hole and then moving the
connecting device with its clip in a direction parallel to an adjacent surface
of
the planar wall section so as to move the planar wall section snugly between
an inner surface of the clip and the rear surface of the plate member.
According to an exemplary embodiment of this connecting device, the
clip is formed from a bent cut-out section of the plate member cut inwardly
from one of the ends thereof and the clip is formed midway between the two
side edges.
According to an other embodiment of the disclosure, a shipping case
for transporting and storing of products is adapted to be collapsed or
disassembled when not in use and to be restored to its full size and shape
when required for shipping purposes. This case includes a case bottom,
sidewalls adapted to extend upwardly from the bottom and adapted for
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connecting to respective side edges of the bottom, and a top cover for
attachment to the sidewalls. At least one of the bottom, the sidewalls and the
top cover has at least one wall section on an inner side thereof which has a
plurality of connecting holes formed therein. The shipping case has at least
one connecting device for connection to the at least one wall section. The or
each connecting device comprises a rigid plate member with means for
securing a product support member thereto and a clip integrally attached to
the plate member and projecting from a rear surface of the plate member.
The clip can be inserted into a selected one of the holes and, after
insertion,
the respective connecting device with its clip can be moved in a direction
parallel to the adjacent planar wall section so as to engage an edge section
of the adjacent wall section in the clip and thereby detachably fasten the
connecting device with the clip to the adjacent wall section.
According to an exemplary embodiment of this shipping case, the clip
is formed from a bent cut-out section of the plate member cut inwardly from
one of the ends thereof and the clip is formed midway between the two side
edges. Further, the clip is bent to form a substantially S-curve extending
from the plate member to a free end of the clip.
These and other aspects of the disclosed shipping case and connecting
devices for use with the shipping case will become more readily apparent to
those having ordinary skill in the art from the following detailed description
taken in conjunction with the accompanying drawings.
So that those having ordinary skill in the art to which the present
disclosure pertains will more readily understand how to make and use the
subject invention, exemplary embodiments thereof will be described in detail
herein below with reference to the drawings.
In the drawings,
Figure 1 is an isometric view taken from above and showing two
sidewalls of a shipping case in accordance with an embodiment of the
invention;
Figure 2 is a detail isometric view showing a corner connector joining
panels of the case of Figure 1;
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Figure 3 is an isometric view of a partially disassembled shipping case
according to Figure 1, this view showing the case bottom and three sidewalls
connected to the case bottom;
Figure 4 is a detail isometric view showing one corner of the partially
5 disassembled case of Figure 3;
Figure 5 is a detail isometric view of a connecting device attached to
an inner surface of a wall panel of the shipping case;
Figure 6 is a top view of one embodiment of the connecting device of
the disclosure;
Figure 7 is a front view of the connecting device of Figure 6;
Figure 8 is a side view of the connecting device of Figures 6 and 7;
Figure 9 is an isometric view showing inner surfaces of a corner
connector for the shipping case;
Figure 10 is a side view of the corner connector of Figure 9;
Figure 11 is a top view of another embodiment of connecting device
according to the present disclosure;
Figure 12 is a front view of the connecting device of Figure 11;
Figure 13 is an isometric view illustrating the connecting device of
Figure 5 attached to one end of a frame member, only an end section of
which is shown;
Figure 14 is a schematic detail top view showing a corner where two
sidewalls of the shipping case are joined; and
Figure 15 is a perspective view taken from above showing a triangular
connector for joining two sidewalls at a top corner.
In the detailed description which follows, exemplary embodiments of a
shipping case and connecting devices for use in a shipping case are
described, particularly with reference to the figures appended hereto.
However, the particularly disclosed embodiments are merely illustrative of
shipping cases and connecting devices according to the present disclosure.
Shown in Figure 1 is a shipping case 10 for the transporting and
storing of products such as automobile and truck parts and components. The
basic case components including its case bottom 12 and its four sidewalls 14
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to 17 are known in the shipping industry and accordingly a detail description
herein is deemed unnecessary except as required for an understanding of the
present invention. The connecting devices disclosed herein for use in and
with the shipping case such as the connecting devices 20 shown in Figure 3
and 5 to 8 are new and are described in detail hereinafter. The case bottom
or base panel 12 of the case can be rectangular and can be constructed of
suitably strong sheet steel which can be galvanized steel, if desired. The
steel
panel or panels 22 can be formed with a series of parallel corrugations as
shown in Figure 3 for added rigidity and strength and the sidewalls 14 to 17
can be corrugated in a similar manner. Thus, the panels 22 can be formed
with flat-topped ridges 24 separated by channels or elongate recesses 26. In
order to elevate the panels 22 of the bottom above the ground or a
warehouse floor, several elongate metal beams or frame members 28 can be
secured such as by welding to the bottom side of these panels. The beams
28 can extend transversely of the case, that is, perpendicular to the length
of
the case as shown in Figures 1 and 3 and they can be hollow to minimize
their weight and have a square or rectangular transverse cross-section. As
shown, the sidewalls 14, 17 are detachably mounted on the case bottom but
they can also be hingedly connected to the case bottom, if desired. As
illustrated, the case bottom is formed with edge channels at 30 which extend
the length of each of the four edges of the case bottom and which have a
width slightly greater than the width of the bottom edges of the side walls so
that these bottom edges will be snugly received in the channels. Elongate
edge frame members 32 can be provided along the top and bottom edges of
each of the sidewalls 14 to 17 and these help to add rigidity to the sidewalls
as well as protect the top and bottom edges of corrugated panels 34 that are
used to form the sidewalls. The bottom frame members 32 of the sidewalls
are adapted for connection to respective side edges of the case bottom. For
example, standard connectors can be used to attach the bottom edges of the
sidewalls to the bottom of the container. It is possible to use suitable
bolts,
such as M8 bolts, that extend through holes formed in the sidewall along the
bottom edge and into nuts welded in position on the bottom (not shown).
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The shipping case 10 is also provided with a top cover 36, the upper
surface of which can be a flat, rectangular panel as shown in Figure 1. In
order to provide improved strength and rigidity to the top cover, this cover
can optionally have corrugated inner panels attached to the flat panel 38.
These internal wall panels (not shown) can be of the same construction as
the corrugated panels 22 and the panels 34. If desired, the top cover can be
formed with edge channels similar to the edge channels 30 formed in the
case bottom to receive the upper edges of the sidewalls and thus support the
sidewalls at their respective top edges.
The upper corners of the sidewalls 14 to 17 can be connected to one
another and to the top cover by means of corner brackets or corner
connectors 40, details of which can be seen from Figures 2, 9 and 10. The
illustrated shipping case 10 is provided with four of these corner brackets,
one at each of the four top corners. Each bracket is constructed from three
metal plates or plate sections, including a first plate 42 which extends
vertically, a second plate 44 which extends vertically and perpendicular to
the plate 42 and a third plate 46. The first plate 42 can be connected to a
respective one of the sidewalls, for example, sidewall 14 by means of two
bolts such as M8 bolts extending through holes 48, 54 formed in the plate.
These bolts are threaded into nuts that are welded onto the sidewall 14.
Similarly, the second plate 44 is detachably connected to its respective
sidewall 15 by means of two bolts that extend through holes 50, 52. These
bolts are threaded into aligned nuts welded to the sidewall 14 adjacent the
corner thereof (not shown). The third plate 46 extends over the corner of the
top cover which has been mounted on the top edges of the four side walls
and thus holds the top cover in place. In the illustrated embodiment of the
third plate, there is an outwardly projecting bump or projection formed in the
top surface of the plate 46. The four bumps of the corner plates help to
locate and hold a shipping case placed on top of a bottom or lower shipping
case. Each dimple can extend into an aligned dimple or hole formed in the
bottom of the case that has been placed on top.
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Each of the first and second plates 42, 44 as shown is formed with a
hook or locking device 60 which is located next to a rectangular opening 62
in the plate. These hooks are used to mount each corner bracket in a corner
of the case bottom 12 when the shipping case has been disassembled (not
shown). A vertical portion 64 of each hook is inserted in the edge channel
which extends along a respective edge of the case bottom. The corner
brackets are used in this manner to support the weight of one or more
collapsed containers that are mounted on top of their respective collapsed
container. The corner brackets also help to hold the sidewalls and the top
cover which have been placed horizontally on the case bottom in their proper
position on the case bottom.
As illustrated, each of the holes in the corner bracket is formed in a
protective recess, including recesses 64, 66 adjacent the bottom edges of the
plates and recesses 68, 70 formed near the top of the corner bracket. By
means of these recesses, the heads of the bolts used to secure the corner
bracket in place are protected as they will not protrude from the adjacent
flat
side of the plate 42 or 44. It will be understood that by the use of these
recesses, damage to the bolts can be avoided during loading, shipping and
unloading of the container.
Turning to Figures 3 and 4, it will be seen that each of the sidewalls 14
to 17 of the case and the case bottom has at least one wall section which can
take the form of an elongate metal plate 76 on an inner side thereof which
has a plurality of connecting holes 78 formed therein. As will be explained
further hereinafter, the holes 78 can be used to detachably connect the
aforementioned connecting devices 20 to the respective sidewall or to the
case bottom. In the embodiment shown in Figure 3, there are two of these
inner wall sections or metal plates 76 formed on the sidewall 16 and four of
these wall sections or metal plates provided along the longer sidewall 15.
Although not visible, it will be understood that the metal plate 76 can also
be
provided on sidewalls 14 and 17. As shown, these metal plates extend
substantially the full height of the sidewall but they can be shorter than the
sidewall or, instead of a single elongate metal plate extending the full
height
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of the sidewall, there could be two or more short plates 76 that are aligned
with one another in the vertical direction. The illustrated shipping case
which
is shown with one wall removed in Figure 3 is also provided with two inner
wall sections or elongate metal plates 80 on the bottom 12, these extending
the length of the case. These plates are also provided with a series of
connecting holes 78. In one embodiment of the case, the holes 78 are square
and measure one inch by one inch. If desired, or if required, metal plates
similar to the plates 76, 80 can also be provided on the inner surface of the
top cover 36 in some shipping cases. In order to rigidly attach the metal
plates 76, 80 in place, their edges can be welded to adjacent top edges of
the ridges 24 of the adjacent panel. Although a series of regularly spaced,
rectangular square holes 78 are shown in the plates 76, 80, it is also
possible
to provide only a few of these holes in each plate, these holes selectively
placed for attaching connecting devices at particular locations. Providing
fastener holes at particular locations can be suitable for a shipping case
designed for only one function, for example, for shipping only particular
parts
or components that are always supported in the case in the same manner.
The advantage of providing a series of holes 78 across the length or the
width of the bottom and across the width or the height of the sidewalls, is
that it permits the shipping case to be used for a variety of purposes because
the connecting devices can be located in a plurality of different locations
inside the case.
Turning now to the construction of the exemplary connecting device 20
illustrated in Figures 5 to 8, this device includes a rigid plate member 90
having two opposite ends 92, 94 and two opposite side edges 96, 98
extending between the opposite ends. A series of fastener holes 100 are
formed in the plate. member. The plate member 90 of Figures 6 to 8 includes
a major planar plate section 102 which can be rectangular or square as
shown and a minor plate section 104 extending at an angle of about 900
from a front side of the major planar plate section 102.
The connecting device 20 further includes an integral clip 110 which is
attached to the plate member 90, projects from a rear surface 112 of the
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plate member, and extends along this rear surface in a longitudinal direction
parallel to the side edges 96, 98. In a particular embodiment of this clip,
the
width and height of the clip is slightly smaller than the corresponding
dimensions of the connecting holes 78, thereby permitting the clip to be
5 easily inserted into a chosen connecting hole in order to attach the
connecting device to an inner surface of the case. In other words, the clip is
sized to be insertable into a selected one of the connecting holes formed in a
planar section of one wall, the bottom or the top of the shipping case. It
will
be understood that this planar section can include the flat, exposed surface
10 of the above described metal plate 76 or the plate 80.
The illustrated clip is formed from a cut-out section of the plate
member 90 cut inwardly from the one end 92 of the plate member. Also, the
illustrated clip is formed midway between the two side edges 96, 98 and this
can help to properly support and orient the connecting device on the wall or
bottom of the container. The exemplary clip 110 is bent to form a
substantially S-shaped curve as can be seen clearly from Figure 8, this curve
extending from the plate member 90 to a free end 114 of the clip which is
spaced from the rear surface 112. The free end is defined by and formed on
an end section 116 of the clip which extends at an acute angle to the rear
surface of the plate member when the clip is viewed from a side edge
thereof. Because the clip is made from somewhat flexible and resilient metal
plate, such as steel plate, the clip is able to flex outwardly from the rear
surface of the plate member when the connecting device is being mounted
on the inner surface of a case wall. In one embodiment, there is a small gap
at 120 between the front surface of the curved central portion of the clip and
the rear surface of the plate member 90. The connecting device 20 can be
detachably connected to the planar wall section, for example, that formed by
the exposed surface of the plate 76 or the plate 80 by first inserting the
clip
110 into a selected connecting hole 78 and then moving the connecting
device with its clip in a direction parallel to an adjacent surface of the
planar
wall section so as to move the planar wall section snugly between the inner
surface of the clip and the rear surface 112 of the plate member. In other
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words, the connecting device is moved into engagement with an edge section
(see for example the edge sections 122 outlined in dash lines in Figure 5) of
the adjacent wall section and thereby detachably fasten the connecting
device.
In an exemplary embodiment and in order to prevent the connecting
device from easily becoming detached from its respective plate member, a
holding tang 125 can be integrally formed on the plate member 90 adjacent
the free end 114 of the clip and projecting rearwardly from the rear surface
of the plate member a short distance. The tang can typically be formed by
punching a generally rectangular hole in the plate member between the clip
and right angle corner 126. The holding tang in use acts to hold the clip
securely in a fully connected position on the planar wall section. The tang
can
accomplish this by engaging the edge of an adjacent hole 78, that is the hole
next to the hole 78 in which the clip has been inserted. The tang will operate
in this manner whether the connecting device is joined to the adjacent wall
section in the upright position shown in Figure 5 or alternatively in an
upside
down position with the minor plate section 104 at the top. Alternatively, in
an
exemplary form of the connecting device and the shipping case, it is possible
to mount each connecting device sideways, this sideways position being
shown by the position of the connecting devices attached to the case bottom
in Figure 3. To explain further, Figure 7 illustrates a longitudinal central
axis
A of the connecting device, this axis extending parallel to side edges 96, 98.
When the connecting device is mounted sideways, the axis A extends
perpendicular to the length of the adjacent elongate metal plate 76 or 80. In
this sideways mounting, the tang can still securely engage or connect the
connecting device by engaging an adjacent edge of the plates 76 or 80. With
reference to Figure 5, these edges that are engaged by the tang are at 130,
132.
The connecting device of Figure 5 to 8 has two shallow channels 134,
136 extending parallel to each other and parallel to the side edges 96, 98.
These channels are located on opposite sides of the clip 110 and have open
channel tops on the rear side of the plate member. At least some of the
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fastener holes 100 are formed in the bottoms of these two channels and, in
the illustrated connecting device, there are three of these holes in each
channel. The channels are provided to allow space for the heads of fasteners
extending through the holes 100, for example, screws or nails. By providing
these channels, the heads of the fasteners do not project beyond the plane of
the rear surface 112. In this way, the plate member 90 is able to fully
engage the adjacent flat surface and is able to be supported thereby when
the connecting member is attached to this surface by the clip.
The exemplary connecting device 20 also has two shallow channels
142 located in the minor plate section 104 and aligned with the channels
134, 136. These channels form upwardly projecting, flat topped ribs 144. The
channels 142 are located on opposite sides of the clip 110 and the open top
of these channels is on the outer side of the minor plate section which is the
bottom side as seen in Figure 5. At least some of the fastener holes 100 are
formed in the channels 142.
Figures 11 and 12 illustrate an alternate form of connecting device for
use on a shipping case such as that illustrated in Figures 1 to 4. This
connecting device 150 has a flat plate member 152 that extends in a single
plane between two opposite ends 154, 156 and between two opposite side
edges 158, 160. The plate member 152 can also be formed with a series of
fastener holes 100 which can extend in two, parallel rows. This connecting
device is also provided with a clip 110 similar to that in the connecting
device
20. The clip of this connecting device also is integrally attached to the
plate
member 152, projects from a rear surface thereof, and extends along the
rear surface in a longitudinal direction parallel to the side edges 158, 160.
Although the illustrated connecting device 150 does not have any shallow
channels such as the channels 134, 136, it can be provided with such
channels, if desired, to accommodate the heads of fasteners.
Figure 13 illustrates how the connecting device 20 can be secured to
one end of a product support member 180, only an end section of which is
shown. The product support member can, for example, be a standard
wooden frame member such as a two inch by four inch frame which is
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commonly used to support products or components in a shipping container.
Either screws or nails 182 can be used to secure the end of the frame
member to the connecting device, these screws or nails extending through
the holes 100. This attachment operation is carried out prior to installation
of
the product support member in the container. It will be understood that
another connecting device 20 can be similarly connected to the opposite end
of the frame member.
Figure 14 illustrates one construction that can be used to interlock the
vertical edges of the sidewalls of the shipping case. This figure shows, as an
example, end sections of two sidewalls 14, 15 which meet at 900 along
vertical side edges. Mounted on the vertical side edge of sidewall 14 is a
locking channel member 184 having an attachment flange 185 that can be
rigidly and permanently connected to the inner surface of the wall. A similar,
slightly smaller channel member 186 is attached to the vertical edge 188 of
the sidewall 15. This channel member also has a connecting flange 190 for
connecting the channel member to an inner surface of the wall 15. The U-
shaped portion of the member 186 is sized to fit snugly within the U-shaped
portion of the channel member 184. It will also be understood that the two
channel members extend substantially the length of each sidewall and thus
these channel members effectively close this vertically extending joint of the
container. Also shown in Figure 14 are two slots 192 formed in the upper
edge of each sidewall at each end. These slots, if provided, can be used in
conjunction with a triangular connector 200 shown in Figure 15.
The connector 200 can be used to temporarily hold the sidewalls in
their correct relative position where they meet at the top corners and prior
to
attachment of the top cover 36. The connector has a triangular, planar main
section 202 having a right angle corner at 204. Downwardly extending edge
flanges are provided at 206 to 209 and the edge flanges 207 and 208 can be
joined along the vertical edge where they meet. These edge flanges extend
substantially perpendicular to the main section 202. A locking tab or tongue
210 is provided between the flanges 206 and 207 and a further locking tab or
tongue 212 is provided between the flanges 208 and 209. The plane of each
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of these tabs is spaced a short distance from the plane of the adjacent
flanges as shown. The tabs extend perpendicular to the main portion 202 and
downwardly therefrom. It will be understood that a connector 200 can be
placed on top of each corner where two sidewalls meet and can then be used
to more securely connect the adjacent sidewalls together at their top corner.
This is accomplished by inserting the tabs 210, 212 in their respective slots
192. When these tabs are inserted, the flanges 206 to 209 extend snugly
along the outside surfaces of their respective sidewalls.
While the present invention has been illustrated and described as
embodied in various exemplary embodiments, ie. embodiments having
particular utility in shipping container applications, it should be understood
that the present invention is not limited to the details shown herein since it
will be understood that various omissions, modifications, substitutions and
changes in the forms and details of the disclosed shipping case and
connectors and their methods of use may be made by those skilled in the art
without departing in any way from the spirit and scope of the present
invention. For example, those of ordinary skill in the art will readily adapt
the
present disclosure for various other applications without departing from the
spirit and scope of this present invention.
