AU737559B2 - Collapsible transport or storage crate - Google Patents

Description

WO 98/47777 PCT/AU98/00272 COLLAPSIBLE TRANSPORT OR STORAGE CRATE.

Field of the Invention This invention relates to a case or crate for transport and/or storage of goods, and in a particularly useful application to a shipping case for stowing multiple loose in shipping containers. The invention is described herein principally in relation to the latter application, but it is emphasised that the invention has general application to transport or storage cases and crates. In this specification, the terms "case" and "crate" are used interchangeably.

Background Art It is the practice in the motor vehicle industry to ship sets of parts for vehicle assembly, for example from a manufacturing plant in one country to an assembly plant in another country, in modular timber shipping cases. These are assembled at a dispatching location and knocked down by the consignee. A widely used form of case is of all timber construction and is assembled from a pallet base and side panels each consisting of a timber frame and an internal plywood lining. The side panels are of varying modular sizes so that the cases, although typically of a uniform width matching the interior width of standard shipping containers, are of varying height and length equal to one quarter multiples of the internal height and length of containers. Nail guns are used to directly attach the side panels to each other and to the floor slats and bearers of the pallet base.

The assembly operation typically takes about 3/2 minutes, while personnel at the PCT/AU98/00272 Received 11 May 1999 D\99081026.5 2 consignee may take up to 9 minutes to dismantle the case using a variety of tools and techniques.

There are limitations on the use of traditional cases, particularly in relation to the strength and carrying capacity of such cases. When goods are exported, or placed into these cases for storage or transportation, it is a requirement that the case be strong enough to withstand the weight of the goods stored therein, as well as the weight of any other case of goods that may be stacked thereupon. A further disadvantage of traditional cases is that the cases require an additional means for strengthening the case so that additional cases of goods can be stacked thereupon. This strengthening means needs to stiffen the case so that it does not bow when placed under pressure.

It is an object of the invention to reduce the above mentioned assembly and knock-down times and so reduce the cost of the shipment process without compromising the reliable delivery of components stowed in shipping cases.

It is also desirable, at least in one or more preferred embodiments of the invention, that assembly of the case requires no on-site tools, thereby enhancing workplace safety.

It is further desirable, at least in one or more preferred embodiments of the invention, that the case can be used as a modular unit in the sense that the top of a case can provide a support for an overlying similar crate.

Summary of the Invention The invention accordingly provides, in a first aspect, a transport or storage case, including: a base of generally rectangular configuration incorporating a floor for the case; a plurality of side frames cooperable to extend about and laterally bound a stowage space above said floor; AMENDED SHEET (Article 34) (IPEA/AU) D\01075019.4 3 means for detachably mounting the side frames to the base, including respective spaced upstanding elements on said base arranged to constrain a respective side frame in a firm fit so that engagement and detachment of the side frame are manually effected, without the aid of tools, by rotate then drop and lift then rotate actions respectively; and link means for disengagably linking said side frames in a pairwise fashion, thereby stabilising the mounting of the side frames to the base.

Preferably, the link means includes a plurality of cooperable peg means each having a peg member manually insertable to effect the link but readily removable for disengagement.

Preferably, the means for detachably mounting each side frame to the base includes cooperable tab and slot means engagable and disengagable in a preferred angular range of relative spatial positions between the base and the side frame, but held against disengagement when the side frames are linked in a 15 pairwise fashion by the link means.

Advantageously, the base includes one or more marginal plates disposed to receive and support the side frames. Conveniently, tabs of the tab and slot means are provided integrally on these plates.

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The base is preferably a pallet including slats defining the floor and spaced bearer members on which the slats are mounted.

In a second aspect, the invention provides a kit of components adapted to be assembled to form the case of the first aspect.

D\01075019.4 4 Brief Description of the Drawings The invention will be further described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is an isometric view from above of an assembled shipping case according to an embodiment of the invention; Figure 2 is an isometric view from above of the pallet base of the case; Figure 3 is a fragmentary view of the base frame; Figure 4 is an enlarged fragmentary view showing a representative one of the peg and slot link units for coupling the side frames together; and .o ln Figures 5 and 6 are enlarged fragmentary sectional views, on the 0: line 5-5 in Figure 1, showing the arrangement for detachably mounting each side frame to the base, respectively in the locked vertical position and in the mounting/detaching position.

15 Description of Preferred Embodiments .:.oei .e illustrated shipping case 10 includes a pallet-type base 12 of generally rectangular configuration incorporating a floor 14 of longitudinally extending timber slats, eg pine, 15, and four generally rectangular side frames 0 20a-20d cooperable to Qe WO 98/47777 PCT/AU98/00272 extend about and laterally bound a stowage space 25 above the floor. The side frames consist of longer main side frames 20a,20b and end side frames 20c,20d. The four side frames are of generally similar construction and the opposite pairs of side frames are substantially identical.

As will be discussed in greater detail below, means is provided for detachably mounting the side frames 20a-20d to base 12 such that both mounting and detachment are manually effected without the aid of tools. Furthermore, link means in the form of three vertically spaced cooperable peg and slot units 30 are provided at each of the four corners of the case for disengagably linking the adjacent side frames in a pairwise fashion, thereby stabilising the mounting of the side frames to the base.

Pallet-type base 12 is of broadly conventional construction, having transverse timber bearers 40 supporting and fixed by nails) to longitudinally extending pine slats 15. The bearers are held clear of an underlying ground or floor surface by further timber slat runners comprising a central runner 43 that extends almost the full length of the base, and side runners 44 which link the bearers in a centre and end pairs. It will be seen that the side and end edges of the runners are offset by a similar spacing from the adjacent edges of the bearers so as to define an all round peripheral rebate 48 of just sufficient width to snugly accommodate the upper edges of the side frames of an underlying case. In this way, the cases may be slightly nested and so used in a modular fashion in that each case may thereby be stably stacked atop another similar case.

Each side frame 20a-20d essentially comprises similar spaced timber uprights of elongate rectangular cross section, top and bottom inwardly open channel steel rails 52,53 and a pair of similar intermediate rails 54,55 in the form of flat steel strips.

Uprights 50 include uprights at the respective ends of each side frame, serving as corner posts 50a. Flat strips 54,55 are multiply slotted at 56 for mounting internal fittings or fastenings as desired. Top and bottom rails 52,53 receive the ends of timber uprights and are fastened to the uprights, but the edges of the flanges of these rails are folded substantially at right angles inwardly towards each other between the uprights, to form return lips 52a, 53a which facilitate handling of the side frames by gripping either rail. It WO 98/47777 PCT/AU98/00272 6 will be noted that top and bottom rails 52,53 are preferably identical so that each side frame can be handled and positioned either way up.

The configuration of peg and slot units 30 is depicted more clearly in Figure 4.

Each corner post 50a of each side frame is fitted with three vertically spaced U-shaped brackets 57. Each bracket 57 is fastened to the post so that its web is proud of the edge of the upright to define an open-ended vertically extending slot or socket 58. Adjacent side frames are linked by coupling adjacent pairs of brackets 57 with a peg member 59 having flat legs 60 arranged at right angles to each other and shaped to snugly fit into slots or sockets 58. These legs 60 are linked at the top by an integral sector portion 61 which is the means by which the peg is gripped and manipulated. A reasonable degree of friction or interference fit is desirable between the pegs 59 and brackets 57 to guard against their inadvertent disengagement during transit, but not to an extent making their removal excessively difficult for the consignee.

In an alternative embodiment, instead of receiving pegs 59, the brackets 57 may include aligned sleeve portions which are coupled by removable cylindrical pegs or pins.

With reference to Figs 5 and 6, the aforementioned means by which the side frames 20a-20d are detachably mounted to the pallet base 12 essentially comprises multiple tab and slot couplings 65. The tabs are formed on flanged marginal support plates 70,71 that are fixed in place, during manufacture of the base, between the bearers and the slats 15. At each of the long sides of the base, there are two such plates 71 extending from the end bearers across the next bearer and terminating part-way across the third bearer from each end. At the shorter sides or ends of the base there is a single such plate 70 arranged centrally symmetrically and lying directly on the end bearer 40 under the ends of the slats. An upturned shallow flange 72 at the outer side edge of each plate 70,71 has two short in-turned tabs 74 at its upper edge which engage complementary slots 75 in the adjacent bottom rail 53 of the respective side frame. (Slots 75 are also provided in top rail 52 for the reason already mentioned, ie. so that each side frame can be handled and positioned either way up).

WO 98/47777 PCT/AU98/00272 7 Opposite each tab 74 are pressed-out tabs 79 which define with flange 72 a channel 69 for locating a bottom rail 53 of a side frame 20. The width of this channel, the relative vertical width of slots 75, and the positions of slots 75 and tabs 74, are such that the side frame can first be introduced at an outwardly tilted or oblique angle (Figure 6) and the respective tabs 74 engaged with the matching slots 75. The side frame can then be rotated to the vertical position and dropped into a firm fit in channel 69 (Figure At this position, the bottom rail 53 of the side frame is sufficiently constrained between the tabs 79 and the flange 72 that the tabs and slots cannot be disengaged except by again lifting the side frame to bring the tabs 74 to the bottom of slots 75, whereupon the side frame can be rotated (Figure 6) over the top of tabs 79 and past the adjacent floor slats Once all four side frames are engaged and in vertical position, the pegs 59 can be dropped into place to link the side frames in pairwise fashion and so stabilise the mounting of the side frames to the base.

If desired, to guard against outward bowing of the side frames, especially the long side frames 20a,20b, the top rails 52 of these side frames may be braced by one or more reinforcing bars (not illustrated). Each bar may have an end formation of rectangular inverted-U configuration shaped to firmly receive and engage top rail 52. A tang in the end formation may be provided, to locate in matching slots 82 in the outer face of the top rail. Means may be provided to latch or lock the or each reinforcing bar in place.

It will be appreciated that stacks of pallet bases 12, longer side frames 20a,20b and end side frames 20c,20d may be delivered to a component dispatch centre of a manufacturing plant. A shipping case may be erected in a very short time from these stacks by withdrawing and readying a base 12, fitting side frames 20 in turn in the manner previously described, and then linking the side frames pairwise with pegs 59.

The case is then ready to be filled and dispatched, if necessary after installing one or more of the spreader bars. If desired, the side frames may be temporarily internally lined in situ by locating suitable panels or sheets of lightweight material such as cardboard against the inside faces of intermediate slotted rails 54,55.

WO 98/47777 PCT/AU98/00272 8 It will be noted that the illustrated arrangement has been provided, and stacking in a nested fashion provided for, without having any undesirable protruding features.

On receipt of the shipping case by the consignee, the latter's personnel may very quickly dismantle the case by removing pegs 59, and then slightly lifting and pivoting the side frames downwardly and outwardly to disengage the bottom rails from their confinement between the tabs 79 and flange 72, whereupon the side frames may be disengaged from tabs 74 and removed. Once the goods have been unloaded from the pallet base, the components of the case may be disposed of or transported in stacks for reuse. This latter option provides a further economic advantage over present practice, where dismantled timber case components, typically damaged to a degree during the dismantling process, are generally disposed of.

In a modification, instead of flanges 72, support plates 70,71 may have upstanding tongues which engage slots in the outer comers of the bottom rails 53. Again, the seating of the bottom rails 53 is preferably reinforced by appropriately positioned press-out tabs in support plates 70,71.

The illustrated shipping case may be dimensioned so that one or more of its principal dimensions (length, width or height) is equal to, or is an integral fraction of, a corresponding internal dimension of a standard shipping container.

Claims (26)

1.(amended) A transport or storage case, including: a base of generally rectangular configuration incorporating a floor for the case; a plurality of side frames cooperable to extend about and laterally bound a stowage space above said floor; means for detachably mounting the side frames to the base, including respective spaced upstanding elements on said base arranged to constrain a respective side frame in a firm fit so that engagement and detachment of the side frame are manually effected, without the aid of tools, by rotate then drop and lift then rotate actions respectively; and link means for disengagably linking said side frames in a pairwise fashion, thereby stabilising the mounting of the side frames to the base.

2. A transport or storage case according to claim 1 wherein said link means includes a plurality of cooperable peg means each having a peg member manually insertable to effect the link but readily removable for disengagement.

3. A transport or storage case according to claim 2 wherein said peg means further includes respective U-shaped bracket means fitted to the upright end edges of the side frames so as to sit proud thereof and thereby define a vertically extending slot or socket to receive said peg member.

4. A transport or storage case according to claim 2 or 3 wherein said peg member having flat legs mutually arranged substantially at right angles, and an integral portion linking said legs, by which integral portion said peg member may be gripped and manipulated.

5. (amended) A transport or storage case according to any preceding claim wherein said means for detachably mounting each side frame to the base further includes cooperable tab and slot means engagable and disengagable in a preferred angular range of relative AMENDED SHEET (Article 34) (IPEA/AU) D'01075019.4 spatial positions between the base and the side frame, but held against disengagement when the side frames are linked in a pairwise fashion by the link means.

6. A transport or storage case according to claim 5 wherein said base includes one or more marginal plates disposed to receive and support the side frames.

7. A transport or storage case according to claim 6 wherein tabs of said tab and slot means are provided integrally on said marginal plate(s).

8. A transport or storage case according to claim 6 or 7 wherein slots of said tab and slot means are provided in metal edge channel rails of said side frames.

9. A transport or storage case according to any one of claims 5 to 8, further •t including at least one elongated marginal plate at each side edge of the •o base, which plate has an upstanding flange with inturned plural tabs of said tab and slot means at or adjacent its upper edge, and o•,-!complementary elongate channel rails defining an edge of each side *Og. frame, said rails each having plural slots of said tab and slot means spaced along a side face of the rail for receiving said tabs at a tilted or oblique orientation of a respective side frame with respect to said base. 20

10. A transport or storage case according to any one of claims 6 to 9 wherein *oog o said marginal plate further includes upturned tab means spaced inwardly of said upstanding flange to define, with the flange, a channel for locating the respective side frame.

11. A transport or storage case according to any preceding claim wherein said base is a pallet including slats defining the floor and spaced bearer members on which the slats are mounted. D\01075019.4 11

12. A transport or storage case according to claim 11, wherein said upstanding elements are provided on marginal plates fixed in place between one or more of said slats and one or more of said bearer members.

13. A transport or storage case according to any one of claims 1 to 4 and 12 wherein said spaced upstanding elements include means defining a channel to receive the respective side frames.

14. A transport or storage case according to claim 13 wherein said means defining a channel comprises a flange extending along the respective side of said base and, inwardly thereof, a plurality of upstanding tabs.

A transport or storage case according to any one of claims 1 to 4 and 12 S: further including a plurality of inturned tabs on one or more of said upstanding elements and complementary slot means in said side frames, o *said slot means being of vertical width to allow relative movement of said 15 inturned tabs therein during said drop and lift actions.

16. A transport or storage case according to any one of claims 1 to 4 and 12, oooo *wherein said spaced upstanding elements include upstanding tongues which engage slots in the bottoms of said side frames, and upstanding tabs which engage the side frames. go 0 20

17 A transport or storage case according to any one of claims 1 to 16 further "e including one or more detachable reinforcing bars configured to embrace and bridge the top edges of opposite ones of said side frames in the assembled condition of the case.

18. A transport or storage case according to any one of claims 1 to 17 wherein said base is provided with a peripheral rebate matched to receive the side frames of an underlying similar shipping case, whereby the case ,may be stably stacked atop such a similar case. D\01075019.4 12

19. A transport or storage case according to any one of claims 1 to 18, wherein each side frame comprises a mixture of metal and wooden frame members.

A transport or storage case according to claim 19 wherein said metal and wooden frame members respectively include metal rails and wooden uprights.

21. A transport or storage case according to claim 19 or 20 wherein said metal and wooden frame members include top and bottom metal channel rails, and wooden uprights received into the channel rails.

22. A transport or storage case according to claim 21 wherein said channel rails have overturned flange edges to facilitate manual handling of the o side frames. o•

23. A transport or storage case according to any one of claim 1 to 22, wherein the case is a shipping case dimensioned so that one or more of its 15 principal dimensions (length width or height) is equal to, or is an integral fraction of, a corresponding internal dimension of a standard shipping S"container.

24. A transport or storage case according to any one of claims 1 to 23, in an assembled form. S: 20

25. A transport or storage case according to any one of claims 1 to 23 as a set or collection of components unassembled. D\01075019.4 13

26. A kit of components adapted to be assembled to form a transport or storage case according to any one of claims 1 to 23, which components include said base, said side frames, said detachable mounting means, and said link means. Toyota Motor Corporation Australia Limited and Fifty-Sixth J.A.F. Pty Ltd By their Registered Patent Attorneys Freehills Carter Smith Beadle 19 March 2001