Flexible parts transporting system

A parts transporting system including a rigid rack frame, a plurality of uprights coupled to the rigid rack frame, a plurality of shelf supports coupled to the uprights, and a plurality of shelf assemblies operably coupled to the uprights and the shelf supports. Each shelf assembly is constructed of a shelf frame and an offset pivot hinge operably coupled to the shelf frame and the shelf support, allowing the shelf frame to swing open at an angle with respect to the rigid rack frame. A lid and strut assembly is operably coupled to each of the shelf frames and includes a lid, a seal covering the entire perimeter of the lid and providing a dirt and moisture resistant seal, and a strut coupled to the lid. Each shelf frame is coupled to a sling assembly which forms compartments used to hold parts. Each shelf frame is positioned directly above each lid except the top lid. When each of the shelf assemblies is emptied, it is lifted, and this action lifts the lid below the shelf assembly, exposing the next layer of parts to be removed.

BACKGROUND OF THE INVENTION
 The present invention relates to a parts transporting system. More
 specifically the present invention relates to a modular flexible parts
 transporting system ideal for parts sequencing procedures involving
 varying part sizes.
 It is frequently necessary to pack articles for shipment to a location
 where the articles are unpacked for assembly with other parts. An
 important aspect of a parts transporting system is its flexibility to
 accommodate parts of different sizes while still maintaining simple
 loading and unloading methods and a stackable shape. Various systems have
 been developed for parts storage and transportation which disclose a parts
 loading system using a compartmental scheme. These systems utilize moving
 rods and shelves to vary the size of their storage compartments. These
 systems are effective in maintaining a flexible configuration of the size
 and number of compartments. However, these systems do not utilize a
 sequenced, pivoting, multi-level, compartmentalized system which decreases
 the difficulty in loading and helps to protect parts. Loading and
 unloading these previous systems is done by placing each part in a
 compartment and then securing the part. The present invention reduces
 these two actions into one thereby reducing the time needed to load and
 unload parts. A system of lids and shelf assemblies are used in the
 present invention to protect, store, and secure parts. The lid and shelf
 assemblies are sequenced so that as each shelf assembly is emptied it is
 lifted and this action will lift the lid below, exposing the next layer of
 parts to be removed. The reverse action of loading is also sequenced so
 that as each shelf assembly is loaded the lid is closed, securing the
 loaded parts and opening the shelf assembly above. Another previous
 storage system discloses a two level storage layout which incorporates a
 pivoting upper deck that serves the dual purpose as a second level of
 storage and a lid for the bottom storage level. However, this system does
 not utilize a compartmentalized storage scheme that sequences, protects,
 and insures the cleanliness of the stored parts.
 SUMMARY OF THE INVENTION
 The present invention possesses shelf assemblies and a compartmental system
 that are easily modified into many different configurations to accommodate
 parts of differing size. The shelf assemblies are sequenced so that when
 parts are removed from each separate shelf assembly, that shelf assembly
 is raised to an elevated pivoted position, thus exposing parts in the next
 lower shelf assembly. An object of the present invention is to maintain
 simple loading and unloading methods no matter what configuration is
 chosen. By creating the sequenced shelf assemblies, the ease of loading
 and unloading parts from the system has been improved.
 A further object of the invention is to maintain the safety and the
 cleanliness of the parts stored in the invention. Often parts are finely
 finished and require special handling to prevent marring or damage during
 transport. This invention protects such vulnerable parts by creating
 sealed flexible storage compartments.
 Further objects, features, and advantages of the invention will become
 apparent from a consideration of the following description and the
 appended claims when taken in connection with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
 FIG. 1 is a perspective view of one embodiment of the present invention.
 The flexible parts transportation system is generally shown as 3 and is
 constructed from a rigid rack frame 7, uprights 19, and shelf assemblies
 21. The uprights 19 are mounted on the rigid rack frame 7 and the shelf
 assemblies 21 are operably coupled to the uprights 19 by universal shelf
 supports 23.
 FIG. 2 is a perspective view of the framework 5 of the flexible parts
 transportation system 3 in accordance with one embodiment of the present
 invention. The framework 5 has a rigid rack frame 7 which constitutes the
 base and determines the footprint of the flexible parts transporting
 system 3. The rigid rack frame 7 is generally rectangular in shape and
 formed in a segmented mold allowing flexible sizing and configuration. In
 one embodiment the mold comprises modular segments allowing any
 dimensional configuration of the rigid rack frame 7 which is a multiple of
 the segment size. The rigid rack frame 7 is preferably formed from sheet
 molded compound although other formable materials including plastics,
 metals, woods, and resins shaped by stamping, molding, carving or cutting
 can be used with equivalent results. The rigid rack frame 7 has recesses 9
 for forklift entry and receptacles 11 for casters or stacking pins. The
 rigid rack frame 7 is designed so that the flexible parts transporting
 system 3 can be moved by an operator rolling it on installed casters, or
 lifting the system with a forklift, handjack or other movement means. In
 one embodiment of the present invention the receptacles 11 are cylindrical
 holes which will accept a caster mounted on a metal pin. In another
 embodiment the receptacles 11 may be used to accept pins 12 located on the
 topside of another flexible parts transporting system 3 (not shown). The
 penetration of these pins 12 into the receptacles 11 will insure a stable
 arrangement when multiple flexible parts transporting systems 3 are
 stacked for shipment.
 The rigid rack frame 7 includes segments 13 whose edges define cavities 17.
 In one embodiment of the present invention there are eight segments 13
 that are located at each comer of the rigid rack frame 7 and in the center
 of each side of the rigid rack frame 7. Uprights 19 are placed snugly into
 cavities 17 in a generally perpendicular manner with respect to the rigid
 rack frame 7 and are securely anchored by a fastening means. The uprights
 19 add structural strength to allow for the stacking of several flexible
 parts transporting systems 3 and provide the basic vertical shape of the
 flexible parts transporting system 3. The uprights 19 of the preferred
 embodiment have a C shaped channel 18 running their entire length which
 provides a surface on which to mount additional components. In one
 embodiment the uprights 19 have an element 20 for securing the flexible
 parts transporting system 3 in a locked down position. The element 20
 could be a metal loop affixed to uprights 19 for use with a portable lock
 or other suitable means.
 FIG. 3 is a perspective view of a second embodiment of the framework 5 of
 the flexible transportation system 3. The rigid rack frame 7 is
 constructed from two sheets, 91 and 93, of corrugated sheet molded
 compound or suitable formable materials that have been shaped to the
 desired dimensions. The bottom corrugated sheet 91 is rotated ninety
 degrees with reference to the top corrugated sheet 93 so that the
 corrugations of sheets 91 and 93 are generally perpendicular to each
 other. The sheets 91 and 93 are then permanently coupled in this position
 to provide the basic structure of the rigid rack frame 7. Brackets 87 are
 then coupled to each corner of the rigid rack frame 7. In one embodiment
 sheet 93 has elevated corrugations 97 on its two ends and sheet 91 extends
 slightly outward from underneath sheet 93 in a direction parallel to the
 corrugations 97 of sheet 93 to create lips 95. Lips 95 extend slightly
 outward from the sides of the rigid rack frame 7 which are perpendicular
 to the corrugations 97. The brackets 87 are coupled directly onto the
 elevated corrugations 97 of the corrugated sheet 93 and rest on lips 95.
 In another embodiment the brackets 87 have flanges 88 that overlap the
 sides of the elevated corrugations 97 and are fastened to the elevated
 corrugations 97. Brackets 89 are coupled to the center of the sides of the
 rigid rack frame 7. In one embodiment sheet 93 has a depressed corrugation
 98 in the center of its shortest side. Brackets 89 are coupled to the
 interior walls of the depressed corrugation 98 by flanges 99 that overlap
 the surface of the elevated corrugations 96 which adjoin the depressed
 corrugation 98. Uprights 19 are then coupled to the brackets 87 and 89.
 Selected uprights 19 coupled to the rigid rack frame 7 provide a mounting
 surface for the universal shelf supports 23 as shown in FIG. 4. Universal
 shelf supports 23 have spring loaded rods 83 and bolts 24 which couple to
 the offset pivot hinges 35 of later added shelf assemblies 21. In one
 embodiment the universal shelf supports 23 are attached to the root
 surface 26 within the C shaped channels 18 in uprights 19, but it would
 also be obvious to one skilled in the art to attach the supports 23 to the
 sides 528 of the channels 18. The uprights 19 which are equipped with
 shelf supports 23 will be determined by the shelf configuration of the
 flexible parts transporting system 3.
 FIG. 5 is a perspective view of a shelf assembly 21 with a single open
 sling. Each shelf assembly 21 includes a shelf frame 37 and a sling
 assembly 39 which is chemically or mechanically connected to the shelf
 frame 37 and hangs downward from the shelf frame 37. The shelf frame 37
 provides support and form for the sling assembly 39 and includes shelf
 frame supports 36 which rest on the shelf assembly 21 immediately below
 It. The shelf frame is also coupled to an offset pivot hinge 35 used to
 later mount the shelf assembly 21 to universal shelf supports 23. The
 sling assembly 39 is preferably made of a flexible material 43 to allow
 for shock absorption during transport. In one embodiment the flexible
 material 43 has a moistureproof coating to seal and protect the parts.
 Further materials can be used which protect the parts from dust or other
 contaminants commonly experienced during shipping and storage at
 manufacturing plants. Also, if the parts require air circulation during
 storage, a mesh can be used as the flexible material.
 The sling assembly 39 can be configured into a single compartment 45 or
 multiple compartments. A permanent or removable dunnage 47 may be used to
 further subdivide the compartment 45 and provide a mechanical means to
 help secure parts. The sling assembly 39 may be coupled to the shelf frame
 37 by mechanical or chemical means as mentioned above. In one embodiment
 the sling assembly 39 is attached to the shelf frame 37 on all exterior
 sides by a J clip. The J clip allows the removal of the sling in a fast
 and nondamaging manner.
 A lid and strut assembly 41 is operably coupled to the shelf frame 37 and
 includes a lid 51, a lid attachment point 52, a linkage 53, and a strut
 anchor 38. In one embodiment the lid and strut assembly 41 is hinged to
 the shelf frame 37 to allow rotation of the lid and strut assembly 41 in
 an upward manner. The strut anchor 38 is an elevated bracket that is
 mounted onto the edge of the lid 51. When in the closed position the shelf
 frame support 36 of each shelf assembly 21 rests upon the strut anchor 38
 immediately beneath it, providing a stable foundation. The lid 51
 completely covers the sling assembly 39 during transport and storage. A
 seal 55 is affixed to the perimeter of the lid 51 providing a dirt and
 moisture seal. The sling assembly 39 in combination with the seal 55
 provides a clean and safe method for the transport of fragile parts. In
 one embodiment of the present invention each compartment 45 of the sling
 assembly 39 may be equipped with a valve 57 to allow easy flushing of
 residue from each compartment 45. In another embodiment of the present
 invention the sling assembly 39 is equipped with a transparent window 59
 or aperture so that stored parts may be viewed when the lid 51 is in a
 closed position.
 FIG. 6 is a perspective view of the shelf assembly 21 with twin slings.
 This embodiment has subdivided the sling assembly 39 into two compartments
 61 by the addition of a shelf sling support 63. In one embodiment the
 shelf sling support 63 is a rod that snaps into the center of the shelf
 frame 37. The compartments 61 are formed when the flexible material 43 of
 the sling assembly 39 is draped over the shelf sling support 63.
 FIG. 7 is a perspective view of the shelf assembly 21 with a center hung
 sling 65. The flexible material 43 is pliant so that when the adjustable
 shelf sling supports 63 are slid in a perpendicular manner along the shelf
 support frame 37 the compartment 67 of the center hung sling 65 may be
 varied in size. Varying the compartment 67 size will allow a secure fit
 for parts of various sizes.
 The flexible parts transporting system 3 is realized when the universal
 shelf supports 23, mounted on uprights 19, are operably coupled to shelf
 assemblies 21. Shelf assemblies 21 are joined to the supports 23 by offset
 pivot hinges 35 which are coupled to bolts 24. The universal shelf
 supports 23 allow the shelf assemblies 21 to swing open at an angle
 relative to the rigid rack frame 7. In a first embodiment of the present
 invention show in FIG. 8, the base has been formed with two short sides
 25A and 25B and two long sides 27A and 27B. Brackets 89 are located in the
 center of the two short sides 25 and brackets 87 are located at each
 corner of the rigid rack frame 7. Uprights 19 having equal vertical
 dimensions are coupled to brackets 87 and 89. Universal shelf supports 23
 are mounted to the uprights 19 coupled to brackets 89. Shelf assemblies 21
 are then operably coupled to the universal shelf supports 23. This
 configuration produces twin shelf assemblies 21A and 21B that swing open
 widthwise in opposite directions A and A'. This twin shelf configuration
 is then repeated with consecutive twin shelf assemblies placed on top of
 each other until the desired or absolute number of shelf assemblies is
 reached. Since the universal shelf supports 23 can be coupled to any
 upright 19 there are numerous shelving configurations which can be
 created.
 The sequencing advantage of this invention is provided by the interaction
 of the shelf assemblies 21 and the lid and strut assemblies 41 as shown in
 FIG. 9. The lid attachment point 52 attaches to the lid 51 and shelf
 assembly 21 above it using linkage 53. In one embodiment of the present
 invention linkage 53 comprises a mechanical connection or chord. As each
 shelf assembly 21 is emptied, it is lifted and this action will lift the
 lid 51 below, exposing the next layer of parts to be removed. Loading is
 the reverse process, starting with all shelf assemblies 21 open and
 loading from the bottom. As each shelf assembly 21 is loaded, its lid 51
 is closed and this action will open the shelf assembly 21 directly above
 the lid 51. This sequencing greatly decreases the time needed to load and
 unload parts because it reduces two actions, moving the shelf assembly and
 moving the lid, into a single action.
 The lid and strut assemblies 41 and shelf assemblies 21 can be locked open,
 closed or in an intermediate position with a lid positioning device 73.
 FIG. 10 is a view of one embodiment of the lid positioning device 73 used
 to hold the lid 51 and shelf assemblies 21 open or closed. The offset
 pivot hinge 35 is operably coupled to the lid positioning device 73. The
 lid positioning device 73 includes a rod assembly 81 and a cam 75 whose
 edges define a first indentation 77 and a second indentation 79. The rod
 assembly 81 is coupled to the universal shelf support 23 and is composed
 of a rod 83 and spring 85 applying a force to the rod 83. When the offset
 pivot hinge 35 rotates, the cam 75 will rotate and the spring 85 will
 force the rod 83 along the edge of the cam 75 until the rod 83 engages the
 first indentation 77 or the second indentation 79. If the rod 83 engages
 the first indentation 77, the lid 51 will be locked open, whereas if the
 rod 83 engages the second indention 79, the lid 51 will be locked closed.
 FIG. 11A illustrates a flexible parts transporting system 3 with a longer
 latitudinal side 102 and a shorter longitudinal side 104. Shelf assemblies
 21A and 21B are of equal size and bisect side 104, dividing the flexible
 parts transporting system 3 into two equal sections and forming hinge line
 103. Sequential shelf assemblies 21 are stacked underneath shelf
 assemblies 21A and 21B and are configured in the same manner. A person of
 ordinary skill in the art would recognize that the shelf assemblies 21A
 and 21 B may be of differing dimensions and may divide the flexible parts
 transporting system 3 into unequal sections shifting the hinge line 103.
 The shelf assemblies 21A and 21B are configured to swing open about the
 hinge line 103 in a longitudinal direction with respect to the flexible
 parts transporting system 3 and in opposite directions with respect to
 each other as indicated by arrows B and C.
 FIG. 11B illustrates a flexible parts transporting system 3 with a longer
 latitudinal side 106 and a shorter longitudinal side 108. Shelf assembly
 21 is the lone shelf assembly visible in this plan view, but sequential
 shelf assemblies 21 configured in the same manner are stacked underneath
 the visible shelf assembly 21. The shelf assembly 21 is configured to
 swing open about hinge line 107 and in a latitudinal direction with
 respect to the flexible parts transporting system 3 indicated by arrow D.
 FIG. 11C illustrates a flexible parts transporting system 3 with a longer
 latitudinal side 112 and a shorter longitudinal side 114. Shelf assembly
 21 is the lone shelf assembly visible in this plan view, but sequential
 shelf assemblies 21 configured in the same manner are stacked underneath
 the visible shelf assembly 21. The shelf assembly 21 is configured to
 swing open about hinge line 113 and in a longitudinal direction with
 respect to the flexible parts transporting system 3 indicated by arrow E.
 FIG. 11D illustrates a flexible parts transporting system 3 with a longer
 latitudinal side 116 and a shorter longitudinal side 118. Shelf assembly
 21 is the lone shelf assembly visible in this plan view, but sequential
 shelf assemblies 21 configured in the same manner are stacked underneath
 the visible shelf assembly 21. The shelf assembly 21 is configured to
 swing open about hinge line 117 and in a latitudinal direction with
 respect to the flexible parts transporting system 3 indicated by arrow F.
 FIG. 11E illustrates a flexible parts transporting system 3 with a longer
 latitudinal side 122 and a shorter longitudinal side 124. Shelf assembly
 21 is the lone shelf assembly visible in this plan view, but sequential
 shelf assemblies 21 configured in the same manner are stacked underneath
 the visible shelf assembly 21. The shelf assembly 21 is configured to
 swing open about hinge line 123 and in a longitudinal direction with
 respect to the flexible parts transporting system 3 indicated by arrow G.
 FIG. 11F illustrates a flexible parts transporting system 3 with a longer
 latitudinal side 126 and a shorter longitudinal side 128. Shelf assemblies
 21C and 21D are of equal size and bisect side 126, dividing the flexible
 parts transporting system 3 into two equal sections and forming hinge line
 127. Sequential shelf assemblies 21 are stacked underneath shelf
 assemblies 21C and 21D and are configured in the same manner. A person of
 ordinary skill in the art would recognize that the shelf assemblies 21C
 and 21D may be of differing dimensions and may divide the flexible parts
 transporting system 3 into unequal sections shifting the hinge line 127.
 The shelf assemblies 21C and 21D are configured to swing open about hinge
 line 127, in a latitudinal direction with respect to the flexible parts
 transporting system 3, and in opposite directions with respect to each
 other as indicated by arrows H and I.
 It is to be understood that the invention is not limited to the exact
 construction illustrated and described above, but that various changes and
 modifications may be made without departing from the spirit and scope of
 the invention as defined in the following claims.