SHIPPING DECKS FOR TRANSPORTING CARGO

PLATEAU D'EXPEDITION POUR TRANSPORT DE CARGAISON

English Abstract

A shipping deck and shipping storage system Is disclosed. The
shipping deck is a generally rectangular tile member formed of a plastic
material.
The shipping deck is substantially planar to support cargo placed thereon. The
shipping deck rests upon three or more adjacent cargo bars and a plurality of
downwardly projecting legs extend from the tile member in order to limit the
movement of the shipping deck and to allow for stacking of the shipping decks
when
not in use. The cargo bars secure within a track which is located on opposite
walls
of the shipping container. The shipping deck, the cargo bars, and the track
within
the shipping container form a system for shipping storage.

Claims

WHAT IS CLAIMED IS:
1. A shipping deck for installation upon three or more adjacent
horizontally spaced apart cargo bars which generally, horizontally,
transversely span
a container used to transport cargo, the shipping deck comprising:
a generally rectangular tile member formed of a plastic material
having:
a substantially planar upper surface for supporting cargo, the upper
surface provided with a series of local depressions formed therein,
a lower surface spaced below the upper surface providing a plurality
of contact regions adapted to rest upon each of the three or more adjacent
cargo
bars, and
a plurality of downwardly projecting legs extending from the lower
surface proximate the contact regions to cooperate with each of the three or
more
adjacent cargo bars to limit movement of the tile member in a forward
horizontal
direction perpendicular to the cargo bar;
wherein a plurality of shipping decks may be stacked in a vertical
manner with the downwardly projecting legs nested within the depressions
formed
in the shipping deck positioned immediately there below.
2. The shipping deck of claim I wherein the tile member is
generally symmetrical about a diagonal line extending between opposed corners.
3. The shipping deck of claim 1 further comprising a series of
handle openings formed through the tile member adjacent to and spaced about an
outer peripheral region of the tile member.
4. The shipping deck of claim 1 wherein the tile member is
formed of injection molded thermoplastic.
5. The shipping deck of claim 1 wherein the tile member is twin
sheet thermo formed from an extruded sheet.
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6. The shipping deck of claim 1 wherein the tile member is
generally square shaped.
7. The shipping dock of claim 6 wherein the tile member is
approximately four foot by four foot square.
8. The shipping deck of claim 1 wherein the tile member is
unitary.
9. The shipping deck of claim 8 wherein the tile member is a
plastic injection molded part.
10. The shipping deck of claim 1 wherein the legs are generally
cup-shaped and downwardly tapered such that the shipping deck may be nested
when
stacked upon a second shipping deck.
11. The shipping deck of claim 10 wherein the tile member adds
an incremental thickness of one to three inches when stacked upon the second
tile
member.
12. The shipping deck of claim 1 wherein the tile member is
provided with an open grate to allow air and liquid to pass through.
13. The shipping deck of claim 12 wherein the legs are each
provided with at least one drain hole to prevent liquid accumulation.
14. The shipping deck of claim 1 wherein the plurality of legs
further comprise:
a plurality of perimeter legs, the perimeter legs being spaced about
a perimeter of the tile member; and
at least one central leg extending from a central region of the tile
member.
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15. The shipping deck of claim 14 wherein the plurality of
perimeter legs further comprise at least four perimeter legs spaced laterally
near a
corner of the tile member.
16. The shipping deck of claim 14 further comprising at least two
central legs wherein the at least two central legs are spaced about a
longitudinal and
a transverse center axis of the shipping deck for receiving a center cargo
bar.
17. A cargo shipping system comprising:
a series of vertical tracks provided along two opposite walls within
an enclosed shipping container, the tracks being spaced apart each providing a
plurality of attachment points at various heights;
at least three cargo bars sized to be received within tracks on opposed
walls, the cargo bars being secured to the track at a common height such that
at least
one shipping deck can be placed thereon creating a generally planar surface;
and
two or more shipping docks sized to fill an area between opposite
walls of a shipping container, the two or more shipping decks each having a
generally rectangular tile member formed of a plastic material each tile
member
having:
a substantially planar upper surface, for supporting cargo placed
thereon, the upper surface provided with a series of local depressions formed
therein,
a lower surface spaced below the upper surface providing a plurality
of contact regions adapted to rest upon the three or more cargo bars, and
a plurality of downwardly projecting legs extending from the lower
surface proximate the contact regions to limit movement of the tile member in
a
horizontal direction perpendicular to the cargo bar.
18. The cargo shipping system of claim 17 wherein the plurality
of legs further comprise:
a plurality of perimeter legs, the perimeter legs being spaced about
an inboard perimeter of the tile member to engage at least two of the
outermost
cargo bars; and
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at least two central legs extending from a central region of the tile
member to cooperate with opposed sides of a centrally located cargo bar.
19. A method of storing shipping decks within a container used
to transport cargo comprising:
providing a first generally rectangular tile member formed of a plastic
material having a plurality of downwardly projecting legs extending from a
lower
surface;
providing a second generally rectangular tile member formed of a
plastic material having a plurality of downwardly projecting legs extending
from a
lower surface; and
stacking the tile members when not in use;
wherein the legs of the second tile member nest within the legs of the
first tile member.
20. The method of storing shipping decks of claim 19 wherein a
single tile member has a height of 2-5 inches and when stacked, the second
tile
member adds an incremental thickness of less than one half of the height of
the tile.
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Description

CA 02610536 2007-11-13
BIEIIPPINGr DECKS FOR TRANSPORTING CARGO
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a shipping deck for installation upon eargo
bars which spans a shipping container used to transport cargo in a multi tier
manner.
2. Background Art
Cargo is comtnonly transl,orted In a variety of cotuainers such as a
scmi-truck trailer, an enclosed truck box, a shipping container, a rail car or
the like.
Frequently, it is not possible to stack cargo or pallets of cargo due to the
nature of
the goods. When the cargo is light, the floor space of the cabin is filled but
load
capacity lms not been reached. In order to increase the amount of cargo that
can be
transported without damagc, cargo bars arc uscd to span the container to stack
multiple tier.s of cargo. Conventionally, plywood deck boards are placed atop
the
cargo bars to form a shclf=lika structure.
SUMMARY OF THE INVIrNTION
The present invention provides a shipping deck which Is used to
transport cargo within a shipping container. One embodiment of the shipping
deck
Is intended to be installed upon three or more adjacent horizontally spaced
apart
cargo bars which span the container. '1'he shipping deck is a gesnerally
reCtatagular
tile member formed of a plastic material. The tile member of the shipping deck
has
a substantially planar upper surface for supporting cargo placed thereon. The
tile
member also has a lower surface spaced below the upper surface. The lower
surface
provides a plurality of contact regions adapted to rest upon each of the tbree
or more
adjacent cargo bars. On the lower surface, a plurality of downwardly
projecting legs
extend proxiniate the contact regions in order to limit the inovemcnt of the
tile
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CA 02610536 2007-11-13
member in a horizontal direction perpendicular to the cargo bar. When not in
usc,
the ahipping deck may be stacked with the legs of a second shipping deck
nested
within corresponding recesses in the upper surfaee of the shipping deck
therebelow
resulting in a low height, stable stack.
In another embodiment, a method of storing shipping decks In a stack
arrangement within a container used to transport cargo is provided, The method
provides nesting the legs of a second tile member within the legs of a first
tile
member. The first and second gcneraily rectangular tile members are formed of
a
plastic rnaterial and each have a plurality of downwardly projecting legs
extending
tYom a lower surface.
The above embodiments, and other embodiments, objects, features.
and advantages of the present invention are readily apparent from the
following
detailed description of embodiments of the invention whan taken In connection
with
the accompanying drawings.
BRIEF DESCRIPTION OF'1'HE DRAWINGS
FIGURE 1 is a view of a shipping container with a system for storage
of cargo therein in accordance with the present invention;
FIGURE 2 is an axiai end view of a shipping container with a system
for storage of cargo therein in accordancc with the present invention;
FIGURE 3 is an axial side view of a siaipping containcr with a system
for storage of cargo therein in accordance with the present invention;
FIGURE 4 is a view of a shipping container with a system for storage
of cargo thcrcin in accordaace with the present invention;
FIGURE 5 is a tcyp surface view of a plastic shipping deck in
accordance with the present invention;
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CA 02610536 2007-11-13
FI.GURE 6 is a side axial view of a plastic shipping dwk in
accordancC with the present invention;
FIGURE 7 is a top surface view of a plastic shipping deck in
accordance with the present invention; and
S FIGURE 8 is a top surface view of a plastic shipping deck in
accordance with the present invention.
DETAILED DLSCRIFTION OF TI3E EMBODIMENTS OF THE INVENTION
As required, detailed embodiments of the present tnvention are
disclosed herein; however, it is to be understood that the disclosed
embodiments are
mercly cxeaaplary of the invention that may be embodied in various and
alternative
forms. The figures are not necessarily to scale; some features may be
exaggerated
or rninimized to show details of particular components. Therefore, specific
structural and functional details disclosed herein arc not to be interpreted
as limitiag,
but merely as a represcntative basis for the claims and/or as a representative
basis
for teaching one skilled in tha art to utilize the present invention.
Referring now to Figure 1, a shipping container is illustrated and
referenced by numeral 18. 'I'hc shipping container 18 has a storage system
located
within It. The storage system has a vertical track series 20 which is attached
to
opposing walls 22, 24 with tracks spacxd at predetcrmined intervals, generally
every
two fcet. The vertical track series 20 runs from the top of each opposing wall
22,
24 to the bottoin with tracks spaced at predetermined intervals, generally
every two
feet. The vertical track series 20 preferably spans the entire length of the
shipping
coutainer 18. Alternatively, one or more horizontal tracks may be provided on
opposcd side walls of the container. A cargo bar 26 is attached at each end to
opposed vertical tracks within the series 20 at both opposing side walls 22,
24.
Addttion-I csgu bars 2&, -90 arc attached to adjacxnt vertical tracks within
the scries
20 at both opposing walls 22, 24. At least three cargo bars 26, 28, 30 may be
at a
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CA 02610536 2007-11-13
uniForm height in order to support a shippi.ng deck 32. Additional cargo bar
sets
may be added tbroughout the shipping container 18 at the sam 1leight, or at a
second or third uniform height to support a second shipping deck 32.
The shipping deck 32 is supported by three cargo bars 26, 28, 30
which are equally spaced. Although equally spaced cargo bars 26, 28, 30 are
illustrated, varying distances between cargo bars are cotitemplated within the
scope
of the present invention when a shipping deck is created according to the
present
invention which is able to rest on the cargo bars. The lower surface of the
shipping
deck 32 eomes into contact with the cargo bars 26, 28, 30. The upper surface
of the
shipping deck 32 supports cargo. Additionally, cargo may be stored underneath
the
shipping deck 32. This increases the amount of cargo a shipping container may
hold.
The shipping deck 32 is a tile member having a generaIIy rec.~tangular
shape. Of course the invention contemplates any number of generally
rectangular
shapes witbin the spirit arid scope of the present invention. Additional
shipping
declcs 32 may bc placed on additional cargo bars throughout the ahipping
container
18 to form a generally planar surPace wherein each shipping deck 32 serves a,c
a tile
member. Additionally, the shipping dcck 32 has multiple legs 34 which extend
downwardly from the lower surface of the shipping deck 32. The multiple legs
are
generally located on opposing sides of each of the cargo bars 26, 28, 30 to
limit the
horizontal movement of the shipping deck 32 within the shipping container 18.
With reference now to Figure 2, an axial end view of the shipping
container 18 of Figure 1 is illustrated with a system of storage of cargo
therein. 'fhe
vertical track series 20 is provided on opposing walls 22, 24 of the shipping
container 18. A cargo bar 26 is attached to the vertical track within the
series 20
at opposite walls 22, 24. The cargo bars 26, 28, 30 as shown in Figure 1,
support
two shipping decks 32.
With reference now to Figure 3, an axial side view within a shipping
container is shown. A shipping deck 36 is fully shown, along with a partial
view
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CA 02610536 2007-11-13
of a shipping deck 36'. This pattern may be repeated many timcs within a
shipping
container to create one tiled surface. Additional shipping decks may be
located at
additional levels within the shipping container.
The shipping decks 36, 36' are supported by three cargo bars 38, 40,
and 42. The shipping decks have legs 44, 46 which limit the borizontal
movement
of the shipping decks 36, 38 within the shipping eontainer. There are
perimeter legs
44 which arc located near the perimeter of the shipping decks 36, 38. The
perimeter
legs 44 are locateci to recxive a cargo bar 38, 42 therebetween. Additionally,
there
are central legs 46 which are generally located in the transverse and
longitudinal
ccntcr of the shipping deck 36. The central legs 46 are sized to receive a
cargo bar
40.
Referring now to Figure 4, a shipping container 48 is illustrated with
a system of storage for cargo therein. The system for storage provides a
horizontal
track 50 on opposite walis 52, 54 of the shipping container 48. Providing a
horicontal track 50 allows flexibility in placing cargo bars 56, 58, 60 and
when
detcrmining a sizc fnr the shipping dcck 62. The cargo bars 56, 60 may be
located
at opposite sides of tlu shipping deck 62 and one cargo bar 58 may be located
near
the center of the shipping deck 62 to support it. The shipping deck 62 has
multiple
legs 64 whieh extend downwardly from the lowcr Furfacc of the sl7ipping deck
62.
The multiple legs are generally located on either side of the cargo bars 56,
58, 60
to limit the horizontal movement of the shipping deck 62 within the shipping
container 48, within the spirit and scope of the present invention.
With reference now to Figures 5 and 6, a shipping deck 66 is
illustrated. Figure 5 is a top view of the shipping deck 66 and Figure 6 is a
side
axial view of the shipping deck 66. The shipping deck 66 may be formed out of
a
thermopiastic in order to roducc the weight of the shfpping deck 66 while
niaintaining its structural integrity. This is desirable in the shipping field
in order
to increase the weight of the cargo. The prior art uses a plywood shipping
deck
which weighs about forty pounds. A shipping deck 66 made of a thermoptastic,
for
example polypropylene, weighs about sixteen pounds. When utilized as a system
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CA 02610536 2007-11-13
filling up a shipping container, the weight of the shipping system is
decreased by
about forty percent, which allows a shipper to increa.ge the weight of cargo
shipped.
Any other suitable plastic is contemplated within the spirit and scope of the
present
invention.
The shipping deck 66 may be manufactured through a variety of
methods such as injection molding, or vacuum forming. Of course any suitable
process to create a plastic shipping deck is contemplated within the spirit
and scope
of the invention. These are automatic processes which allow for mass
production
of the shipping decks 66,
The thermoplastic shipping deck 66 has an, upper surface 68 and a
lower surface 70. The upper surface 68 supports the cargo and is generally
planar.
The upper surface 68 may be a unitary surFace. The upper surface 68 may have a
series of holes in it, which form a grate as illustrated. This design a,ilows
for air and
liquid to pass through the shipping deck 66. In the prior art, a plywood
shipping
deck absorb liquid, wh9ch tnay cause the plywood shipping deck to become moldy
or have a foul odor. '1'hus, having a plastic shipping deck 66 which does not
absorb
liquids and may easily be cleaned with water and allowed to self dry is ideal.
Handle holes 71 are molded into the deck 66 at convenient locations.
The upper surface 68 of the shipping deck 66 may also have with a
scrics of local depressions 69 Formed therein. The local depressions 69 formed
in
the upper surface 68 are gencraily located above the multiple legs 72. 74.
The multiple lcgs 72, 74 extend downwardly from the lower surface
70. The legs 72. 74 have a generally cup shape and are tapered so as to have a
larger opening at the top than at the bottom. Local depressions 69 formed in
the
upper surface 68 are located generally above the legs 72, 74. The local
depressions
69 may bc sized to receive legs of a second shipping deck, which makes thc
shipping
decks nestable, and adds an incremental thickness when stacked upon the first
tile
member. The incremental thickness may be one to three inches. Adding an
incremental thickness of less than two inches is preferred. This allows for
easy
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CA 02610536 2007-11-13
storage of a large amount of shipping decks when they are not in use. This is
an
improvement over the prior art shipping decks because they are not stackable
in a
stable manner. The prior art shipping decks also take up a great deal of space
when
not in use.
The lcgs 72, 74 have at ]cast one hole In their respective surfaces.
This allows for liquid to pass through the legs 72, 74 so that the liquid does
not
accumulate inside the lcgs 72, 74. The legs 72, 74 are generally located in
two
different areas. There are perimeter legs 72 which are located near the
perimeter of
the shipping deck 66. The perimeter legs 72 may bc located near a corner of
the
shipping deck 66. There are also central legs 74 which are generally located
near
a longitudinal and transverse center of the shipping deck 66. At least two
central
legs 74 are provided and up to four centCal legs 74 are contemplated within
the
scope of the invention. When at least two central legs 74 are provided, the
central
legs 74 may be located across a longitudinal axis or a transverse axis or
both.
Near the perimeter of the shipping deck 66 at least two hand holes 76
are provided. A series of hand holcs 76 is illustrated around the entire
perimcter of
the shipping deck 66. Locating the handle holes 76 near the perimeter of the
shipping deck 66 allows for easy handling of the shipping deck 66.
The shipping deck 66 may be square as illustrated. The shipping
deck 66 may have a length of four feet with a width of four feet.
Rcferring now to Figure 7, interlocking embodiment of a shipping
deck 78 is illustrated. The shipping deck 78 is a generally rectangular shape.
The
shipping deck 78 has two sides where two projections 80 extend beyond the
general
perimeter of the shipping dcck 78, On the other sides of the shipping deck 78
are
recesses 82 where the two projections 80 of an adjacent deck may interlock.
This
would help to create a generally planar surface when the shipping decks 78 are
a
part of a system for shipping within a shipping container. The shipping deck
also
may include legs 84, 86, which allow the shipping dcek 78 to stack upon a
second
shipping deck, within the scope and spirit of this invention.
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CA 02610536 2007-11-13
Now referring to Figure 8, yet another embodiment of a shipping
deck 86 is illustrated with a top Qucface view. The shipping deok 86 ia a
getierally
rectangular shape. The shipping deck 86 t'na,y include lcgs 88. 90 which may
allow
the shipping deck 86 to stack upon a second shipping deck, within the spirit
and
scope of the current invention. The shipping deck 86 may also have at least
two
hand holes 92 located near the perimeter of tho shipping deck 86.
The shipping deck 86 may be twin shcet thermo formed from
extruded sheet. The shipping deck may be formcd with a top layer 94 and a
bottom
layer 96. The top layer 94 and bottom layer 96 may be held together by using
an
edge flange 100 and posts 102, which join the top layer'94 and the bottom
layer 96
via a weld or an adhesive joint. The top layer 94 and bottom layer 96 have a
hollow
cavity 98 therebetween.
In sumniary, the present invention provides shipping decks used
within a storage system to transport cargo which are stackeble when not in
use, light
in wcight, casy to clcan, easy to roanufaeture, and provide sound structucal
integrity.
While embodiments of the invention have been illustrated and
described, it is not intended that these embodiments illustrate and describe
all
possible forms of the Invention. Rather, the words used in the specification
are
words of description rather than limitation, and it is understood that various
changes
inay be made without departing troin the spirit and scope of the invention.
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Representative Drawing