Abstract:
A low-profile shipping system for shipping an object without a pallet includes a shipping crate configured to surround the object being shipped. The shipping crate is configured to substantially enclose the object being shipped. The shipping crate defines a first passageway and a second passageway. The first passageway and the second passageway are adapted to receive a fork of a forklift. The low-profile shipping system also includes a shipping rail attached to the inside of the shipping crate at a location above the first passageway and the second passageway. The shipping rail is adapted to support the weight of the object and the shipping crate while the object is being transported by forklift.

Description:
FIELD OF THE INVENTION 
       [0001]    This disclosure relates generally to a low-profile shipping system for transporting large heavy objects without the use of a pallet. 
       BACKGROUND OF THE INVENTION 
       [0002]    Typically, large heavy objects, such as superconducting magnets, are transported in crates that have either external integrated pallets or are set on pallets. The pallets provide a stiff platform suitable for lifting the heavy object and the pallets are also used to secure the crate during transportation. It is typically necessary to use a thick pallet when moving a heavy object to ensure that the pallet has enough stiffness and strength to support the heavy object and the crate. For example, a typical pallet used to transport a superconducting magnet may be 6 to 8 inches in thickness. 
         [0003]    There are several problems with using a conventional crate and pallet to ship large heavy objects. Since the pallet is necessary to both move and secure the crated object, the thickness of the pallet poses an issue at every step of the transportation process. For example, when shipping large heavy objects by air the cargo aircraft has fixed dimensions. If the combination of the pallet and crate exceed the available height of the aircraft, then a larger aircraft or an alternate method of transportation must be used. Additionally, not all airports can handle the large aircraft. Therefore, additional shipping methods, such as truck or rail, must be used to get the object to its final destination. The need to use large aircraft for transportation adds both to the transportation costs and to the total time to deliver the object. In the case of a superconducting magnet, the additional shipping time results in additional cost due to the increased boil-off of the liquid cryogen, such as liquid helium, used to cool the magnet. It is much cheaper to fill a superconducting magnet with liquid helium at the manufacturer&#39;s facility as opposed to at the installation site. Therefore, increasing the transportation time for certain goods, such as superconducting magnets, may result in substantially higher costs. For these and other reasons, there is a need for a new low-profile shipping system for the transportation of large heavy objects such as superconducting magnets. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0004]    The above-mentioned shortcomings, disadvantages and problems are addressed herein which will be understood by reading and understanding the following specification. 
         [0005]    In an embodiment, a low-profile shipping system for shipping an object without a pallet includes a shipping crate configured to surround the object being shipped. The shipping crate includes a front panel shaped to at least partially define a first pair of ports that are adapted to receive a fork from a forklift. The shipping crate also includes a rear panel shaped to at least partially define a second pair of ports adapted to receive the fork from the forklift. The low-profile shipping system also includes a shipping rail attached to the inside of the shipping crate. The shipping rail is adapted for attachment to the object being shipped. 
         [0006]    In an embodiment, a low-profile shipping system for shipping an object without a pallet includes a shipping crate configured to substantially enclose the object being shipped. The shipping crate is shaped to define a first passageway and a second passageway. The first passageway and the second passageway are adapted to receive a fork of a forklift. The low-profile shipping system also includes a shipping rail attached to the inside of the shipping crate at a location above the first passageway and the second passageway. The shipping rail is adapted to support the weight of the object and the shipping crate while the object is being transported by the forklift. 
         [0007]    In another embodiment, a low-profile shipping system for shipping an object without a pallet includes a shipping crate configured to substantially enclose the object being shipped. The shipping crate includes a generally rectangular bottom panel. The shipping crate includes a first pair of spacers attached to the bottom panel and a second pair of spacers attached to the bottom panel. The shipping crate includes a first block attached to the first pair of spacers. The first block and the first pair of spacers collectively define a first passageway. The shipping crate includes a second block attached to the second pair of spacers. The second block and the second pair of spacers collectively define a second passageway. The first passageway and the second passageway are both adapted to receive a fork from a forklift. The low-profile shipping system also includes a shipping rail attached to both the first block and the second block. The first shipping rail is adapted to be attached to the object being shipped. 
         [0008]    Various other features, objects, and advantages of the invention will be made apparent to those skilled in the art from the accompanying drawings and detailed description thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a schematic representation of a low-profile shipping system in accordance with an embodiment; and 
           [0010]      FIG. 2  is a schematic representation of a perspective view of a low-profile shipping system in accordance with an embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0011]    In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments that may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments, and it is to be understood that other embodiments may be utilized and that logical, mechanical, electrical and other changes may be made without departing from the scope of the embodiments. The following detailed description is, therefore, not to be taken as limiting the scope of the invention. 
         [0012]      FIG. 1  is a schematic representation of a low-profile shipping system  10  in accordance with an embodiment. The low profile shipping system  10  includes a shipping crate  11  and one or more shipping rails ( 36 ,  38 ) (shown in  FIG. 2 ). The shipping rails ( 36 ,  38 ) will be described in more detail hereinafter. The shipping crate  11  includes a bottom panel  12 , a top panel  14 , a front panel  16 , a rear panel  18  (shown in  FIG. 2 ), a first side panel  20 , and a second side panel  22 . The front panel  16 , the rear panel  18 , the first side panel  20  and the second side panel  22  may all be attached to the bottom panel  12  in a substantially perpendicular manner. The shipping crate  11  may be made from plywood reinforced with 2×4s according to an embodiment. The shipping crate  11  may be constructed from different materials according to other embodiments. The bottom panel  12  is generally rectangular in shape according to an embodiment. The bottom panel  12  may be shaped to have a plurality of openings  13 . Each of the plurality of openings  13  is adapted to allow the passage of a securing member, such as a cable or a strap, from either the one or more shipping rails ( 36 ,  38 ) or from the heavy object being transported directly to the vehicle used for transporting the heavy object. According to an embodiment, there may be two openings on the side of the bottom panel  12  that is adjacent to the front panel  16  and two openings on the side of the bottom panel  12  that is adjacent to the rear panel  18 . According to other embodiments, one or more of the plurality of openings adapted to pass a securing member may be located on the front panel  16 , the rear panel  18 , the first side panel  20  or the second side panel  22 . 
         [0013]    The front panel  16  may be shaped to partially define a first pair of ports  23 . According to the embodiment shown in  FIG. 1 , the bottom panel  12  is also shaped so as to help define the first pair of ports  23 . The rear panel  18  (shown in  FIG. 2 ) is shaped so as to define a second pair of ports  25  (shown in  FIG. 2 ). A first passageway  26  is defined between one of the first pair of ports  23  and one of the second pair of ports  25 . A second passageway  28  is defined between the other of the first pair of ports  23  and the other of the second pair of ports  25 . The first passageway  26  and the second passageway  28  pass completely through the shipping crate  11  according to an embodiment. The first passageway  26  and the second passageway  28  are both positioned within 4 inches from a bottom surface  30  of the low-profile shipping system  10  according to an embodiment. According to other embodiments, the first passageway  26  and the second passageway  28  may be positioned at higher locations on the shipping crate. The first passageway  26  and the second passageway  28  are both configured to receive a fork from a forklift in order to move the low-profile shipping system  10 . 
         [0014]      FIG. 2  is a schematic representation of a perspective view of the low-profile shipping system  10  shown in  FIG. 1 . Common reference numbers will be used between  FIG. 1  and  FIG. 2 . In order to better illustrate the interior of the low-profile shipping system  10 ,  FIG. 2  shows the low-profile shipping system  10  without the front panel  16  (shown in  FIG. 1 ). It should be appreciated by those skilled in the art, that the low-profile shipping system  10  will include a front panel  16  according to most embodiments. 
         [0015]      FIG. 2  more clearly illustrates the construction of the low-profile shipping system  10  in accordance with an embodiment. The first side panel  20  may have a top surface  32  that is not parallel to the bottom surface  34 . For example, the top surface  32  may be angled or curved so as to more closely conform to the object being transported in the low-profile shipping system  10 . The second side panel  22  may have a top surface that is the same shape as the top surface  32  of the first side panel  20 . 
         [0016]    The low-profile shipping system  10  also includes a first shipping rail  36  and a second shipping rail  38 . The low-profile shipping system  10  may also include a first block  39 , a second block  40 , a third block  41 , and a fourth block  42 . The first block  39  and the third block  41  are attached to a first pair of spacers  43 . The second block  40  and the fourth block  42  are attached to a second pair of spacers  44 . In accordance with an embodiment, the first pair of spacers  43  are attached to the bottom panel  12 . The first block  39  is attached to one of the first pair of spacers  43  via a plate  45 . The plate  45  allows for a user to easily adjust the height of the block, and therefore the first rail  36 , with respect to the bottom panel  12 . The second block  40 , the third block  41 , and the fourth block  42  may also be mounted with a plate in a manner similar to that described for the first block  39 . According to the embodiment shown in  FIG. 2 , the blocks ( 39 ,  40 ,  41 ,  42 ) use a plate, such as the plate  45 , for mounting on one side and are mounted to either the first side panel  20  or the second side panel  22  on the other side. 
         [0017]    Referring to  FIG. 1  and  FIG. 2 , the first pair of spacers  43 , the first block  39  and the third block  41  further define the first passageway  26 . The first passageway  26  passes all the way through the shipping crate  11 . The second pair of spacers  44 , the second block  40 , and the fourth block  42  further define the second passageway  28 , which also passes all the way through the shipping crate  11 . According to an embodiment, the first pair of ports  23  (shown in  FIG. 1 ), the second pair of ports  25  and the blocks ( 39 ,  40 ,  41 ,  42 ) may all help define a passageway with a generally constant height and width. However, according to other embodiments, the height and width of the passageway may be variable. For example, the height and width of the first pair of ports  23  and the second pair of ports  25  may be greater than the height defined by the blocks ( 39 ,  40 ,  41 ,  42 ). In other words, the first pair of ports  23  and the second pair of ports  25  may define a larger opening than that defined by the blocks ( 39 ,  40 ,  41 ,  42 ). The passageways ( 26 ,  28 ) pass all the way through the shipping crate  11  in accordance with the embodiment shown in  FIGS. 1 and 2 . 
         [0018]    According to an embodiment, the first shipping rail  36  and the second shipping rail  38  may each be made from steel. The shipping rails ( 36 ,  38 ) shown in  FIG. 2  are L-shaped in cross-section, but materials with different cross-sections may also be used. The shipping rails ( 36 ,  38 ) are configured to be attached to an object (not shown) that is to be shipped using the low-profile shipping system  10 . The shipping rails ( 36 ,  38 ) are adapted to be rigidly attached to the object such as by bolts through a plurality of bolt holes  46 . As discussed previously, it may be advantageous to first bolt the first shipping rail  36  and the second shipping rail  38  to the object and then to secure the shipping rails ( 36 ,  38 ) to the bottom panel  12  by way of one or more plates  45  and spacers ( 43 ,  44 ). According to other embodiments, the shipping rails ( 36 ,  38 ) may connect to a different portion of the shipping crate  11 . For example, the shipping rails ( 36 ,  38 ) may connect to one or more of the bottom panel  12 , the front panel  16 , the rear panel  18 , or the top panel  14 . 
         [0019]    As was previously discussed, the plurality of openings  13  are adapted to allow a securing member (not shown) such as a cable or strap to pass through. The plurality of openings  13  allow the securing member (not shown) to secure the shipping rails ( 36 ,  38 ) or the heavy object directly to the bed of a vehicle used for transportation. For example, by running the securing member from either the first shipping rail  36  or the second shipping rail  38  directly to the vehicle, both the object and the low-profile shipping system  10  may be attached to the transportation vehicle with greater security. Those skilled in the art will appreciate that securing the object to a vehicle via a shipping rail is much more secure than packing the object in a conventional crate, securing the crate to a pallet, and then attaching the pallet to the vehicle via straps. By attaching the object via the shipping rails ( 36 ,  38 ) the object is much less likely to move around and put additional strain on the shipping crate  11 . 
         [0020]    Referring now to both  FIG. 1  and  FIG. 2 , as previously described, the first passageway  26  and the second passageway  28  are both shaped to receive the fork of a fork lift. Once the fork of the forklift is inserted into the first passageway  26  and the second passageway  28 , the blocks ( 39 ,  40 ,  41 ,  42 ) provide a load path to the shipping rails ( 36 ,  38 ). According to an embodiment, the shipping rails ( 36 ,  38 ) are long enough to at least partially overlap the first passageway  26  and the second passageway  28 . This helps to transfer the weight of the object (not shown) from the shipping rails ( 36 ,  38 ) to the fork of the forklift. Since the low-profile shipping system  10  is shaped to define two passageways ( 26 ,  28 ) and because the shipping rails ( 36 ,  38 ) support the weight of the object, it is not necessary to use a pallet when using the low-profile shipping system  10  to transport the object. 
         [0021]    According to an embodiment, the low-profile shipping system  10  may be used to transport a superconducting magnet for a magnetic resonance imaging system. The low-profile shipping system  10  does not require the use of a pallet and, therefore allows for a significantly lower overall height. For example, an exemplary magnet that may be shipped using the low-profile shipping system  10  weighs approximately 13 tons and is 93 inches tall. According to an embodiment, the low-profile shipping system  10  used to transport the exemplary superconducting magnet may be 96 inches tall. If the exemplary magnet were shipping in a conventional crate with a pallet, the total height of the pallet and the shipping crate would be around 110 inches tall. The lower overall height of the low-profile shipping system  10  allows the object to be transported in a wider variety of vehicles, which can save a significant amount of money on transportation costs. Additionally, it is logistically much easier to move a crate that does not require the use of oversized vehicle for transportation. According to the example of a magnet for a magnetic resonance imaging system, the magnet is typically filled with an expensive cryogen, such as liquid helium. Liquid helium has a low boiling point, and tends to evaporate very quickly. If the transportation of a superconducting magnet takes too long, then significant amounts of liquid helium will boil off and require expensive replacement. Therefore, the low-profile shipping crate has the potential to offer considerable savings when used for the shipping of superconducting magnets. It should be appreciated by those skilled in the art that the low-profile shipping system  10  may be adapted to transport objects other than superconducting magnets. Any object with enough structural integrity to be supported by one or more shipping rails ( 36 ,  38 ) may be transported with the low-profile shipping system  10 . However, the low-profile shipping system  10  may prove especially useful for the transportation of objects that are on the verge of being oversized and/or those objects that would be significantly less expensive to transport if they were crated in a manner that was shorter than the combination of a conventional crate and a pallet. 
         [0022]    This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.