Shipping Container with Shelves

A shipping container includes a first wall assembly and a first shelf support member secured to the first wall assembly. The first shelf support member includes a first shelf bearing portion. A second shelf support member is secured to the first wall assembly, and is separate from and spaced apart from the first shelf support member. The second shelf support member includes a second shelf bearing portion. A first slot is defined adjacent to the first shelf bearing portion on the first shelf support. A second slot is defined adjacent to the second shelf bearing portion on the second shelf support. A shelf member includes a first tab and a second tab, the first tab being fixed within the first slot, and the second tab being fixed within the second slot. A portion of the shelf member spans a distance between the first and second shelf support members.

TECHNICAL FIELD

The present invention relates generally to shipping and storage containers, and more particularly to a novel shelf assembly within such a container.

BACKGROUND OF THE INVENTION

Many different shipping container designs have been developed over the years, some having relatively elaborate interior shelf and article-positioning systems. One such example is found in U.S. Pat. No. 5,667,090 to Langham et al., which discloses an octagonal shipping container for shipping stackable manufactured articles. The Langham container includes a plurality of attached slotted wall panels defining an interior storage cavity. Langham further discloses a plurality of shelf arms which project through the slots to engage goods positioned in the storage cavity. Langham represents one method of storing and shipping stackable manufactured articles, in particular steering wheels. However, there is always room for improvement. For instance, the Langham container must be laid on its side upon a support fixture for loading, necessarily increasing the time and effort required to place articles into, or remove them from, the container. Further, Langham requires a separable fastener to secure the sides of the container.

Co-owned U.S. Pat. No. 6,832,562, herein incorporated by reference in its entirety, describes a shipping container for stackable articles. The container includes a base assembly, a plurality of side assemblies, to top assembly, and a plurality of shelf assemblies. The base assembly, side assemblies, and top assembly are preferably constructed of a multiple layer, corrugated laminate, and are attachable to one another, defining an interior storage space. Each shelf assembly includes a plurality of shelf support blocks with a plurality of face sections distributed along a length, and a shelf flap. The shelf assemblies are secured to the sidewall assemblies, and positioned in the storage space to engage manufactured articles, for example sunroofs, positioned therein. The design of this container provided certain advantages including the elimination of wood augmentation in the container, thereby meeting customer requirements that mandated the elimination of wood due to infestation concerns. Furthermore, the likelihood of damage to articles shipped within this container was substantially reduced due to the enhanced strength of the shelf assemblies. The load time of sunroofs, for example, was also substantially reduced given the prefabricated shelf assemblies within this container. Nevertheless, continued goals include providing even stronger shelf assemblies, and reducing the manufacturing complexity associated with shipping containers.

It is thus desirable to construct a container for stackable goods that can be easily assembled and loaded, yet is strong and durable. The present invention addresses one or more of the limitations or problems associated with the related art.

SUMMARY OF THE INVENTION

In one aspect of the embodiments described herein, a container for shipping and storing manufactured articles is provided. The container includes a base and a container body portion secured to the base. The container body portion defines an interior of the container. A first wall assembly is secured to the container body, the first wall assembly including a first shelf assembly protruding into the interior. The first shelf assembly includes a first shelf support member and a second shelf support member spaced apart from the first shelf support member, for supporting at least one shelf member. A first shelf member includes a first end and a second end, a first tab at the first end, a second tab at the second end, a first flap, and a first aperture. First and second bearing portions for supporting the first shelf member are also provided. The second bearing portion is positioned adjacent the first bearing portion. The first and second bearing portions are formed integral to the first shelf support member. The first and second bearing portions define a first slot therebetween. The first tab is fixed within the first slot. Third and fourth bearing portions are also provided for supporting the first shelf member. The fourth bearing portion is positioned adjacent the third bearing portion. The third and fourth bearing portions are formed integral to the second shelf support member. The third and fourth bearing portions define a second slot therebetween. The second tab is fixed within the second slot.

In another aspect of the embodiments described herein, a shipping container is provided. The container includes a first wall having a first shelf support member, the first shelf support member including a first plurality of adjacent and integral shelf bearing portions. The first wall also includes a second shelf support member, the second shelf support member being separate from and spaced apart from the first shelf support member. The second shelf support member includes a second plurality of adjacent and integral shelf bearing portions, each one of the second plurality of shelf bearing portions corresponding to one of the first plurality of shelf bearing portions. A first plurality of slots is provided, each slot of the first plurality of slots being defined between two adjacent shelf bearing portions of the first plurality of shelf bearing portions. A second plurality of slot is also provided, each Slot of the second plurality of slots defined between two adjacent shelf bearing portions of the second plurality or shelf bearing portions. A first plurality of shelf members extends between the first and second shelf support members, each shelf member comprising a first tab, a second tab, a third tab, and an aperture. Each first tab is fixed within one slot of the first plurality of slots. Each second tab is fixed within one slot of the second plurality of slots. Each third tab mates with an aperture of an adjacent shelf member.

In another aspect of the embodiments described herein, a wall assembly for a shipping container is provided. The wall assembly includes at least one wall portion and a first shelf support member secured to the at least one will portion. The first shelf support member includes a first shelf bearing portion. A second shelf support member is also secured to the at least one wall portion. The second shelf support member is separate from and spaced apart from the first shelf support member. The second shelf support member includes a second shelf bearing portion. A first slot is defined adjacent to the first shelf bearing portion on the first shelf support. A second slot is defined adjacent to the second shelf bearing portion on the second shelf support. A shelf member includes a first tab and a second tab, the first tab being fixed within the first slot, and the second tab being fixed within the second slot. A portion of the shelf member spans a distance between the first and second shelf support members.

In another aspect of the embodiments described herein, a wall assembly for a shipping container is provided. The wall assembly includes a first shelf support member including a first shelf bearing portion and a second shelf bearing portion. The first and second shelf bearing portions define a first notch therebetween. A second shelf support member includes a third shelf bearing portion and a fourth shelf bearing portion. The third and fourth shelf bearing portions define a second notch therebetween. At least one shelf member has a first end and a second end. The shelf member includes a first portion extending along a length of the shelf member, the first portion including a first tab at the first end, and a second tab at the second end. The first tab is fixed within the first notch and the second tab is fixed within the second notch. The at least one shelf member is fixed about the contours of the second and fourth shelf bearing portions.

DETAILED DESCRIPTION

FIGS. 1-16illustrate one embodiment of a container10for use in storing, shipping, and protecting any of a variety of substantially flat components or sub-assemblies (for example, sunroofs mountable in automobile assemblies.) In the embodiment disclosed herein, unless otherwise stated, components of the container are formed using known processes from one or more laminated layers of a corrugated material, such as a corrugated board or paper material. However, the use of alternative materials, such as wood, polymers, or metals is also contemplated. In addition, unless otherwise stated, known methods of joining together pieces of corrugated material, such as nailing, gluing or adhesive application, stapling, bump stitching, and other known methods are all contemplated for use in assembling the container and components described herein.

FIG. 1illustrates a base12of the container10. Base12comprises a frame portion12a(for example, a corrugated laminate pallet, or a wooden shipping pallet) and a container bottom portion12b. Bottom portion12bhas a body12cand a plurality of flaps12dformed along edges of body12e. Bottom portion12bmay also be formed from a sheet of corrugated material cut to form flaps12d, which are then folded upward and secured to each other as shown to form a tray-like structure. The bottom portion is then nailed, glued, stapled, or otherwise secured to frame portion12a.

Referring toFIG. 2, a body portion14of the container is positioned and secured within base portion12. Body portion14has a rear wall portion14aincluding a pair of opposite side edges, and a side flap14battached to each of the rear wall opposite edges. Base flaps14eare formed along a bottom edge of rear wall portion14aand along bottom edges of each of side flaps14b. Base flaps14care secured to base portion body12cand to base portion flaps12d, thereby attaching the body portion14to the base. Body portion14may be formed from a sheet of corrugated material cut to form side flaps14band base flaps14cwhich are then folded as shown and secured to base portion body120and to base portion flaps12d. Taken together, tear wall portion14aand side flaps14bdefine a portion of an interior of the container.

Referring toFIG. 3, a rear stop portion16is secured to an interior surface of rear wall portion14ato provide a cushion or shock absorbing member for articles inserted into and stored in container10. Rear stop portion16may also occupy dead space between rear wall portion14aand edges of the components stored in the container, thereby aiding in immobilization of the components stored in the container. Rear stop portion16may be formed from a sheet of corrugated material cut to size and folded as shown to produce a shock-absorbing wedge16atherein. The rear stop portion is then positioned and secured to rear wall portion14aof body portion14. Alternatively, team or other padding may be secured to rear wall portion14aof body portion14to provide the desired cushioning effect.

Referring toFIGS. 4-8, a left wall assembly20and right wall assembly22of the container are provided for supporting the components to be stored and shipped in the container. Wall assemblies20,22each include respective wall portions20a,22a, a plurality of shelf support members or portions24secured to wall portions20a,22a, and a plurality of shelf portions18secured to wall portions20a,22aand supported by shelf support members24. As shown inFIG. 4, each of wall assemblies20and22is attached to body portion14by attaching or fixing a respective one of wall portions20a,22ato an associated one of the side flaps14b, using adhesives, staples, or any other suitable means.FIG. 5Ashows left wall assembly20along a left-hand margin of the drawing.FIG. 5Bshows the components of left wall assembly20in an exploded view adjacent the assembled view inFIG. 5A.FIG. 5Cshows right wall assembly22along a left-hand margin of the drawing.FIG. 5Dshows the components of right wall assembly22in an exploded view adjacent the assembled view inFIG. 5C. Attachment of a wall assembly to a respective wall portion and attachment of the wall portion to an associated side flap14bforms an associated wall of the container.

FIG. 6is a plan view of a laminate of multiple layers of corrugated material for use in forming shelf support members24of the present invention, shown prior to cutting into individual shelf support members.FIG. 7is a perspective view showing a laminated shelf support member24of the container10of the present invention cut to shape. Each shelf support member24is formed from multiple individual layers24sof corrugated material stacked and secured to each other to form a laminated structure. The pre-cut laminate block ofFIG. 6and the post-cut support member24shown inFIG. 7each have a thickness T in the direction of stacking (which extends in a direction perpendicular to the plane of the drawing inFIG. 6, and which is shown in perspective inFIG. 7). The thickness T can have any desired value depending on the requirements of a particular application, and depends on the thicknesses of the individual layers forming the laminated structure and the number of layers. Shelf support members24may be formed as shown inFIGS. 6 and 7, wherein one or more sheets24sof corrugated material are stacked and secured to each other in the stacked condition. Then, the outer edges and interior of the stack of attached sheets inFIG. 6is cut along interior portions thereof as shown to provide adjacent profile shapes24pforming the bearing portions24aand slots24bof the shelf support members24. The profiled laminate block may then be cut lengthwise into sections along lines24x(shown inFIG. 6) to provide multiple individual shelf support members24(one of which is shown inFIG. 7). For example, using the laminate arrangement ofFIG. 6, eight shelf support portions24as shown inFIG. 7may be cut from a single laminate block.

The laminate may be formed to any desired thickness, subject to any process limitations, to provide a desired degree of strength to the shelf support member. As seen inFIGS. 6 and 7, in one embodiment, each shelf support portion24includes a plurality of bearing portions24a, with a slot24bformed between adjacent ones of bearing portions24a. In the embodiment shown, bearing portions24aeach have a saw-tooth configuration or wedge shape which provides a relatively strong base in the region of the bearing portion which is under the greatest mechanical stresses, due to the weight of the part being supported. Slots24bare dimensioned (in conjunction with tabs18fon shelf portions18, described in greater detail below) so as to provide an interference fit with tabs18finserted therein, thereby providing additional structural stability to the container.

FIG. 8is a plan view of a blank structured for cutting to provide a pair of shelf portions. InFIG. 8, cut lines are shown as solid lines and fold lines are shown as dashed lines. Referring toFIGS. 8 and 16, shelf portions18are provided which span a distance between adjacent shelf support members24along an associated one of wall assemblies20and22, thereby providing substantially continuous support of the stored components along the lengths thereof when they are positioned and secured within the container. Shelf portions18may be formed as shown inFIG. 8, wherein one or more sheets of corrugated material are stacked and secured to each other in the stacked condition so as to form a blank. Then, the outer edges and interior of the blank or stack of attached sheets is cut to the shape shown and then cut down the center thereof (along line18a) to form a pair of shelf members18which are symmetrical about cut line18a. Portions of the stack defining the tabs18fmay be cut along lines18wto enable the tabs to be bent or flexed with respect to the remainder of the shelf portion18when attaching the shelf portions18to associated shelf support portions24during assembly of the container.

In one method of assembly of wall assemblies20,22, one or more of each of wall portions20aand22aare provided. If multiple wall portions are used, the wall portions20aare stacked on each other and secured together to form a first stacked wall portion assembly, and the wall portions22aare sacked on each other and secured together to form a second stacked wall portion assembly. For each of the wall portion assemblies, a single wall portion may be used, or any desired number of the wall portions may be stacked on one another to provide a support base of sufficient thickness and strength to support shelf support members24in the manner described herein.

First and second shelf support members24are then attached to the stacked wall portions20asuch that the support members24extend parallel with each other, and such that each bearing portion24aon one of the first and second shelf support members24is aligned with an associated bearing portion24aon the other one of the first and second support members24, in addition, third and fourth shelf support members24are attached to the stacked wall portions22asuch that the support members24extend parallel with each other, and such that each bearing portion24aon one of the third and fourth shelf support members24is aligned with an associated bearing portion24aon the other one of the third and fourth support members24. Shelf portions18are then attached to the shelf support members in the manner described below.FIG. 15is a side view of portions of opposed wall assemblies20and22of a shipping container in accordance with one embodiment described herein.FIG. 16is a schematic exploded perspective view of a portion of a wall in accordance with an embodiment of the present invention, showing the daisy-chaining and folding of adjacent shelf portions18.

The following description applies equally to wall portion assemblies termed by stacking wall portions20atogether or by stacking wall portions22atogether. Referring toFIG. 16A, in a particular embodiment, a pair of all portions22a-1and22a-2is stacked (as shown inFIG. 6) so that a vertically-extending edge22gof wall portion22a-1overlaps a vertically-extending, edge22eof wall portion22a-2along an edge S1of the stack, and a vertically-extending edge22fof wall portion22a-2overlaps a vertically-extending edge22hof wall portion22a-1along another edge S2of the stack. In this configuration, the overlapped edges22eand22hare spaced apart a distance D5. In addition, shelf support members24are secured to the innermost wall portion22a-2such that outermost longitudinal edges of the support members24are aligned with the overlapped edges22eand22hand are spaced apart the distance D5as shown inFIG. 16A. This arrangement allows a maximum spacing of the support members24for a given length L5of the wall assembly, while still enabling attachment of the support members24to a stacked or relatively thicker portion of the wall portion assembly, rather than attaching one or more of the support members24to a portion of the assembly comprising a single layer22aof material.

Referring toFIGS. 8, 15 and 16, shelf portions18are folded along folds18band18c(FIG. 8), to substantially conform to the profile of bearing portions24a(FIGS. 6 and 7) of shelf support portions24. Successive ones of shelf members18are then connected or daisy-chained together by fixing or inserting tab18dfrom one shelf portion18into slot or aperture18eof an adjacent shelf portion18, thereby creating a continuous, accordion-like shelf structure. “Fixing” may mean simply inserting the tab or flap18dinto the corresponding aperture18eof the next adjacent shelf member18. Or, “fixing” may mean to glue or otherwise ensure that flap18dis snugly fit within aperture18eof the subsequent or adjacent shelf member18. This shelf structure may be easily positioned to follow the contours defined by shelf support bearing portions24a, by bending tabs18fout of the plane of the shelf section on which they are formed, and inserting the tabs18finto corresponding slots24bformed or defined between adjacent bearing portions24aof shelf support portions24. Tabs18fare formed in positions along shelf portions18such that insertion of the tabs into slots24bforces the shelf portion structure to bend according to the contours of the shelf support portion. When all of tabs18fhave been inserted into associated slots24b, the tabs are bent back into the plane in which they were originally formed, during which a formed end of each shelf portion18wraps over a corresponding surface of a bearing member24aof shelf support portion24. Shelf portions18are now supported at each end thereof by a bearing portion24a. Shelf support portions24may then be positioned along wall portions20a,22aand glued or otherwise secured to the wall portions. InFIG. 15, the portions of walls20and22are shown spaced more closely together than in an actual shipping container, in order to convey the arrangement of the opposed shelf portions18with respect to each other. The wall portions are also magnified to show how the shelf portions18are folded about the shelf support portions24.FIGS. 15 and 16also show the daisy chaining of adjacent shelf portions18by inserting tab18dof a first shelf portion into a slot or aperture18eof an adjacent shelf portion, as described in above.

Each shelf portion18is also folded so that adjacent shelf portions18may be daisy-chained together by inserting tab18dfrom one shelf portion18into slot or aperture18eof an adjacent shelf portion18. As understood in the art, “daisy-chaining” involves directly connecting identical or similar components in a chain-like structure. For example, in components or pieces each having first and second portions usable for connecting the component to adjacent, similar or identical components, the first portion of component A will be connected to the second portion of an adjacent component B, and the second portion of component A will be connected to the first portion of an adjacent component C. Components B and C are also similarly connected to adjacent similar or identical components spaced apart from component A. Thus, each piece in the chain is directly connected only to either one or two distinct and immediately adjacent pieces. As applied to the shelf portions18described herein, daisy-chaining is accomplished by inserting tab18dfrom one shelf portion18into slot or aperture18eof an adjacent shelf portion18, as shown inFIGS. 15 and 16

Other assembly methods or sequences are also contemplated. For example, shelf support portions24may be secured to wall portions20a,22aprior to attachment of shelf portions18thereto. When walls20,22are complete, each wall is secured to a corresponding side flap14bof body portion14.

FIG. 14Ashows an exploded view of a front30of the container.FIG. 14Bis an assembled view of the front portion of the container shown inFIG. 14A. Front30comprises a body30aand a plurality of flaps30bformed along edges of body30a. Front30may be formed from a sheet of corrugated material cut to form flaps30b, which are then folded and secured to each other as shown so as to wrap over corresponding front edges of walls20,22. One or more shock absorbing positioning members30dsuch as rear stop portion or a foam padding, similar to that provided along rear wall14a, may be secured to an interior surface of front30as shown inFIG. 14. In addition, if desired, optional corner pieces100may be applied to one or more exterior corners of the container (at the intersections of body30aand flaps30b) to provide an additional degree of rigidity to the container.

FIG. 9shows application of an optional sub-cover31to a top portion of the container. Sub-cover31comprises a body31aand a plurality of flaps31bformed along edges of body31a. Sub-cover31may be formed from a sheet of corrugated material cut to form flaps31b, which may then be folded over and secured to exterior surfaces of associated ones of wall assemblies20and22. The sub-cover31may be used to provide an additional degree of rigidity to the container and to aid in supporting the cover top (described below) if desired.

FIGS. 10-13show various stages in the final assembly of the shipping container10.FIG. 10is a schematic front view looking into an interior of the container after application of optional sub-cover31to the container. If desired, optional corner pieces100may be applied to one or more exterior corners of the container to provide an additional degree of rigidity to the container.

FIG. 11is a partial exploded schematic view showing attachment of the front30of the container to the wall assemblies20and22of the container. Front30may be attached to side wall assemblies20and22using adhesives, staples, or any other suitable method.

FIG. 12shows application of top or cover32to the container. Top32comprises a body32aand a plurality of flaps32bformed along edges of body32a. Top32may be formed from a sheet of corrugated material cut to form flaps32b, which are then folded and secured to each other as shown to form a top which may be wrapped over upper edges of walls20,22, rear wall portion14aand front30.

It should be understood that the present description is for illustrative purposes only, and should not be interpreted to limit the scope of the present invention in any way. Thus, those skilled in the art will appreciate that various modifications to the disclosed embodiments might be made without departing from the intended spirit and scope of the present invention, which should be given the full breadth of the claims and any and all equivalents thereof. For example, a preferred embodiment has been illustrated as having four walls, however, the shelf assembly that is an object of the present invention might find application in three sided or many sided containers, or even as a separate stand alone shelf. As discussed above, substantial variations might be made to the number and positioning of shelf assemblies within the container, allowing goods of differing shapes and sizes to be positioned in the same container, for instance, sunroofs for different vehicle models. Further, the presently disclosed shelf assembly could find application in containers designed not for shipping, but for permanent storage or display of manufactured articles. Other objects and features of the present invention will be evident upon an examination of the attached drawing figures and appended claims.