Method and apparatus for unloading non-palletized cargo units of bales of hay

An apparatus for unloading non-palletized units of cargo from cargo containers without docking facilities comprising an elongated mounting bracket for detachable attachment to a bottom door frame of a cargo container, and having a plurality of mounting studs extending outwardly therefrom, a pair of support rails having sockets at one end for receiving and detachably attaching to the mounting studs, and upstanding support legs at the other end for supporting the rails in a horizontal position, and a towing link for attachment at one end to a cargo unit to be pulled onto said rails and attachable at the other end to towing apparatus for towing the cargo unit onto said rails.

BACKGROUND OF THE INVENTION 
The present invention relates to the packaging and shipping of high density 
bales of hay, and pertains particularly to a method and apparatus for 
unloading of non-palletized units of multiple high density compact bales 
of hay from cargo containers in remote locations. 
There has, in recent years, developed an international market for 
domestically produced hay. In order to meet the needs of this market, the 
hay must be packaged to provide for efficient and economical handling and 
shipping. Such economical handling and shipping requires that the 
packaging be in high density units capable of efficient packaging into 
shipping containers, efficient mechanical handling, and easily convertible 
to manual handling. This also requires that the bales also be of 
substantially uniform size and weight and formable into selectable uniform 
weight and size cargo units: 
In the aforementioned U.S. Pat. No. 5,001,974, a system and method is 
disclosed for recompacting or further compacting bales of hay into higher 
density bales for shipping in international trade. The application also 
discloses cutting them into smaller, lighter weight units for easier 
manual handling. That system provides high density, smaller, more easily 
handled cargo units which are desirable for both ease of loading and 
fitting into cargo space and for manual handling. However, it is also 
desirable that these units be substantially equal or uniform in size and 
weight and be easily formed into selected uniform size and weight larger 
units for mechanical handling and shipping. 
The typical harvesting of hay involves cutting it and drying it in the 
field, after which it is typically compressed and bound into bales for 
easier handling and storage. In the past, the typical field baled bale of 
hay for local use typically weighs about fifty-five to seventy-five pounds 
and occupies a space of about 48".times.23".times.17". The weight may vary 
by as much as 20% under certain circumstances. Bales of this size and 
weight are generally considered suitable for local manual handling and 
storage. However, they are considered too bulky for commercial markets and 
for long distance shipping, particularly for overseas shipping. For this 
reason, the standard commercial bale is about one-hundred ten pounds and 
of about the same dimensions as above. Twenty of such bales weigh a 
standard or metric ton of about twenty-two hundred pounds. 
It has been found that such bales weighing fifty Kg or one-hundred ten 
pounds can be compacted into a single bale of about 
18".times.24".times.20". This is about the same width and height and less 
than one-half (1/2) the length of the standard bale. This size and weight 
bale has a density of about twenty-two pounds per cubic foot. These can 
also be split into 18".times.12".times.20" bales and stacked and bound 
into fractions of one ton, one ton and multiple ton, such as two to twenty 
ton units for shipment. Also, two bales of the twenty-five Kg or 
fifty-five pounds weight standard dimension can be compacted into a single 
bale of the aforesaid size and weight. This recompacting or rebaling 
conserves considerable cargo space and provides easier handling units for 
manual handling, but requires some form of unitization for existing 
mechanical cargo handling and loading equipment, such as forklift trucks. 
One form of unitization now used is the mounting of bales of hay on wooden 
pallets for handling with a forklift truck. The bales are frequently tied 
or attached to the pallet by means of straps, webbing, netting and by 
shrink wrap polymer films. However, the pallets take up valuable cargo 
space and weight and require separate handling and accommodation. They are 
also of a standard size and restrict or predetermine the size of a cargo 
unit. Moreover, they are an added cost, not only as a unit but as to 
handling and space requirements. 
In our co-pending application Ser. No. 07/526,186, filed May 18, 1990, 
entitled "METHOD AND APATUS FOR UNITIZATION OF CARGO", we disclose a 
method of unitizing multiple bales of hay for handling by means of a 
forklift truck without the need for a pallet. That method is more fully 
discussed hereinbelow. 
The shipping of cargo of this type in international trade requires 
flexibility in the size of cargo units, as well as a standardization that 
can be fit into different size cargo spaces. For example, most cargo is 
shipped in cargo containers of a standard 8'.times.8'.times.40'. However, 
when they reach their destination, they must fit cargo spaces that may 
vary from about four to about ten feet in width and from about five to 
about forty feet in length. They must also be in units of weight that are 
standard, and can be accommodated by vehicles at the destination, which 
can vary from one-quarter ton to ten ton capacity. 
The cargo containers can be transported from shipping docks on a truck 
trailer chassis to the ultimate consumer, e.g. a dairyman or rancher. 
However, most dairies and ranches do not have suitable loading and 
unloading dock facilities to enable conventional forklift truck unloading. 
It is desirable that improved means be available for the unloading of bales 
of hay in suitable size and weight unitized cargo from cargo containers in 
remote locations without dock facilities. 
SUMMARY AND OBJECTS OF THE INVENTION 
It is the primary object of the present invention to provide an improved 
system for the unloading of bales of hay in suitable size and weight 
unitized cargo units from cargo containers in remote locations without 
dock facilities. 
In accordance with a primary aspect of the present invention, a cargo 
support frame comprises a pair of cargo support rails and an attachment 
bracket for attachment to the rear of a cargo container for supporting 
cargo units in a position for removal by means of a forklift truck. The 
cargo units are provided with towing attachment means to enable the units 
to be towed from the container onto the cargo support frame. 
Another aspect of the invention comprises a method of unitizing a cargo of 
multiple high density hay bales into a non-palletized cargo unit capable 
of being handled by a forklift truck without a pallet, and including 
towing means comprising the steps of selecting a plurality of 
substantially identical high density bales of hay, arranging said 
plurality of bales of hay into a stack of at least one layer of multiple 
horizontal rows, embodying attaching means for a towing cable into the 
stack, and wrapping multiple layers of an elongated continuous sheet of 
pre-stretched polymeric film having a memory solely horizontally around 
said plurality of bales of hay for forcing the bales into binding 
engagement with laterally adjacent bales for forming a unit of cargo 
capable of being handled by forklift trucks without a pallet.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
Referring to the drawings, particularly to FIG. 1, there is illustrated a 
preferred embodiment of the apparatus of the present invention shown in 
use in carrying out the method of the invention. As illustrated in FIG. 1, 
a portable dock assembly, designated generally by the numeral 10, is shown 
attached to the rear end of a standard universal cargo container 12 that 
is supported on trailer unit 14. The portable dock assembly, as best seen 
in FIGS. 1-3, comprises an elongated base or mounting bracket 16 for 
attachment to the support frame of the shipping container, and a pair of 
generally T-shaped support rails, designated generally by the numeral 18, 
for detachable attachment to the base mounting bracket. The base or 
mounting bracket 16 comprises a central angle iron bar section 19 having a 
plurality of mounting blocks or studs 20, 22, 24 and 26 for receiving the 
ends of the rails 18, as will be explained. 
The base mounting bracket 16 includes a pair of attachment assemblies, one 
at each end of the bar 19. These attachment assemblies each comprise a 
base plate 28 and 30, respectively, secured to the end of the bar 19 and 
extending longitudinally outward therefrom. These are identical in 
construction and only one of which will be specifically described. The 
coupling unit 28 comprises a substantially oval shaped disc 32 mounted on 
a forward end of a rotatable shaft 34 journaled in the plate 28, and a 
handle 36 on the outer end thereof for manual rotation thereof. The disc 
32 is slightly smaller than and of a shape like that of locking holes or 
openings 38 in mounting blocks on the corners of the shipping container. 
When properly oriented, the disc 32 is inserted through the hole or 
opening 38, and is rotated by the handle 36 so that it is at ninety 
degrees to the orientation of the oval opening or hole 38, and thus locks 
against the back of container mounting bracket 40. 
The coupling assembly 30 on the opposite end of the bar 19 is of an 
identical mirror image construction, and is adapted to engage a coupling 
hole or opening 42 on the opposite corner of the shipping container. As 
shown in FIG. 2, each of the mounting brackets 28 and 30 are provided with 
blocks 44 and 46 that extend over and aid in supporting the mounting 
bracket on the frame structure below the door opening of the shipping 
container. 
The T-shaped support rails 18 in the illustrated embodiment are each formed 
of a downwardly facing C-channel section, with an upper elongated 
horizontally extending support rail portion 48 having an open forward end 
for coupling to a stud of the bracket 19, and including a cross or 
transverse throughbore 50 for receiving a pin 51. The rails may have any 
suitable cross sectional configuration, but preferably have a flat support 
surface of about nine (9) inches in width. Each of the blocks or studs 
20-26 similarly have a pin receiving bore for registering with the bore 50 
and receiving pin 51. The support rails include a downwardly depending leg 
52, preferably near the outer end thereof, with a foot or base plate 54 
thereon. An angled brace between the rail and leg may be provided if 
necessary. The legs 52 preferably include a telescoping lower portion 56 
with suitable means, such as multiple bores 58 and 60 that enable the 
length of a leg to be adjusted. This is to provide for leveling of the 
rail portion 48 of the support rails. This compensates for uneven terrain 
on which the trailer carrying the cargo container may be parked. 
As illustrated in FIGS. 1 and 10 the portable dock unit is attached to the 
base frame of the cargo container unit, and extends outward from the usual 
rear door thereof substantially even with the floor or deck thereof. This 
provides at least a pair of spaced apart support rails forming an 
extension of the container floor or deck on which a cargo unit can be 
pulled and supported. This portable dock unit enables the unloading of the 
cargo units from a trailer supported container in the absence of 
traditional docking facilities. 
The present invention apparatus was designed to provide portable docking 
facilities for unloading shipping containers in remote locations where 
conventional docking facilities are not available. These permit the use of 
forklift trucks for lifting, handling and unloading cargo units, 
particularly unitized bales of hay as set forth in our parent U.S. Pat. 
No. 5,090,177. The present apparatus was designed to provide a system and 
method for shipment of units of cargo, particularly unitized bales of hay, 
with mechanical handling by a forklift truck from the loading dock to the 
ultimate consumer. To this end, bales of hay are unitized as in the parent 
U.S. Pat. No. 5,090,177, and are equipped with towing means and connecting 
means as illustrated in FIGS. 6-8. 
Referring to FIG. 6, a tow coupling kit is illustrated comprising a pair of 
identical cables 62, each having a large loop 64 on one end and a small 
loop 66 on the other end. The large loop is to extend around a plank or 
board 68, which serves as anchoring device positioned behind the bales of 
hay in the stack, as shown in FIG. 7, with the connecting loops 66 
extending across the layer of bales and extending forward of the front 
face of the stack. This towing and coupling connection need be provided 
only in the lower units of cargo, that is the bottom units. 
Referring to FIG. 7, a stack is shown being formed by first laying down a 
first layer of multiple bales 70, arranged as illustrated, forming 
multiple rows of multiple bales in a rectangular array. The tow coupling 
unit is placed as illustrated, with the loop 64 extending over the 
opposite ends of the board or plank 68, and positioned with the cables 
lying on top of a center portion of the layer of bales, and the loop 66 
extending forward of the front face of the stack. Thereafter, a second 
layer of bales 70 is placed on top of the first layer, thereby forming a 
multi-layer stack of multiple bales formed in multiple rows forming 
multiple rows of vertical columns of bales. The stack is then bound 
together and formed into a non-palletized unit of cargo consisting of 
multiple bales of hay bound together by a continuous lateral force 
directed inward on the peripheral sides of the stack. This continuous 
force is applied by pre-stretched polymeric film wrapped solely around the 
sides of a stack a sufficient number of times times, on the order of about 
four to about ten times for applying sufficient force to bind the bales 
together. The inward force forces the bales against laterally adjacent 
bales, and binds them together against vertical movement relative to one 
another and the binding sheet. This forms a palletized unit of cargo 
capable of being handled and lifted solely by the spaced apart tines of a 
forklift truck. 
A towable cargo unit, as thus constructed, is illustrated by the numeral 
76. Referring now to FIG. 9, this non-palletized unit ties a stack of 
bales of hay and is paired with a second non-palletized unitized stack 78, 
and loaded by means of a lift fork truck 80 having a pair of spaced apart 
tines 82, only one of which is shown, extending beneath and engaging the 
lower surface of the stack of hay. The forklift truck may be driven into 
the cargo shipping container, as shown in FIG. 9, placing the cargo units 
against the forward bulkhead of the container. The container may be 
resting on a ground surface, as shown in FIG. 9, or may be supported on a 
trailer unit, as in FIG. 10, with means such as a loading dock enabling 
the forklift truck to drive into the shipping container. 
Referring to FIG. 10, there is illustrated the cargo shipping container 
positioned on a transport trailer in the absence of conventional docking 
facilities. In this situation, a forklift truck is capable of removing the 
cargo units disposed adjacent the door. However, it cannot remove those 
positioned forward of the door without some means as provided herein. 
As illustrated in FIG. 10, unloading of the shipping container is easily 
accomplished with the loading of units of cargo as described above. In 
this instance, a cable 86 is attached at one end to the forklift truck 80, 
such as to the lift structure 82 or the like, and is attached at the other 
end to the loops 66 of the cables 62 embedded in the cargo unit 76. The 
lift truck 80 is then backed away from the rear of the container to tow 
the cargo units 76 and 78 from a position inside the shipping container 12 
to a position as shown in phantom on top of the support rails 48. In this 
position, the forks 82 of the forklift truck 80 may be extended beneath 
the cargo unit 76, and engage the bottom surface thereof directly, and 
thereby lift the entire combination of units 76 and 78 from their 
position, and move it to a desired location, such as a warehouse or the 
like. Thus, the system provides an effective means for mechanically 
handling a cargo unit from its inception to its ultimate destination. This 
is carried out without the need for space consuming load pallets or 
difficult to apply top and bottom sheet type pallets. 
In operation, when a shipping container 12 is positioned at its ultimate 
destination, a docking kit as illustrated in FIG. 3 is selected, and the 
base plate 16 is attached to the bottom rear frame of the shipping 
container. At least two support rail assemblies are then selected and 
attached to a pair of the studs 20-26. Thereafter, a forklift truck or 
other suitable towing vehicle is attached to the bottom cargo unit, as 
illustrated in FIG. 10, for towing the cargo unit onto the support rails 
48. Thereafter, the forks of a forklift truck are engaged underneath the 
cargo unit, lifting it from its support on the rails, and placing it in 
its desired location. This, as previously noted, eliminates a considerable 
amount of manual handling of cargo and eliminates the need for a loading 
dock at the ultimate destination. 
While we have illustrated and described our invention by means of specific 
embodiments, it should be understood that numerous changes and 
modifications may be made therein without departing from the spirit and 
scope of the invention as defined in the appended claims. We further 
assert and sincerely believe that the above specification together with 
the accompanying drawings contains a written description of the invention 
and the manner and process of making and using it, in such full, clear, 
concise, and exact terms as to enable any person skilled in the art to 
which it pertains, or with which it is most nearly concerned, to make and 
use the same, and further that it sets forth the best mode contemplated by 
us for carrying out the invention.