Adjustable suspended roll packaging system

A base platform carrying a plurality of lower rail members on an upper surface. A pair of opposing laterally spaced end plates engaging the lower rail members. A series of lower positioning teeth formed in the lower rail members. A series of complementary lower connecting teeth included on the end plates engaging the lower positioning teeth. A plurality of upper rail members carried by the end plates. A series of upper positioning teeth formed in the upper rail members. A series of complementary upper connecting teeth included on the end plates engaging the upper positioning teeth of the upper rail members securing the end plates to the upper rail members. The series of upper and lower connecting teeth provide for the end plates to be repositionable along at least a portion of the upper and lower rail members to adjust spacing between the end plates to accommodate various roll sizes.

BACKGROUND OF THE INVENTION

1) Field of the Invention

The present invention relates to crate packaging systems, and more particularly, to an adjustable suspended roll packaging systems for storing and shipping large rolls of wound sheet material, such as fabric or plastic, which are carried on elongated cores.

2) Description of Related Art

In various manufacture industries, sheet material such as fabric is often shipped in elongated cylindrical rolls utilizing a supporting elongated core. This is also true for the shipping of plastic film and other such materials that can be wound around an elongated core. Difficulty arises from the material handling viewpoint in that the sizes of the material being shipped can vary in the length of the cores, as well as the width. The variations in the material sizes generally depend upon the particular requirements of the customer and thus require custom packaging solutions for a given roll.

The prior art largely teaches systems in which the elongated material rolls are shipped on pallets having fixed dimensions. The rolls are positioned in end plates having a central opening for receiving the elongated cores. The end plates are secured to the pallets at pre-defined locations, and are not adjustable or repositionable. Accordingly, since the material rolls often vary in length, different sizes of pallets are used to ship the material rolls and a large quantity of different size pallets must be kept in inventory.

The use of pallets having various sizes is inconvenient and expensive. To accommodate for the various sizes of rolls which may be required to be shipped, every warehouse may have over 50 different types of pallets on hand having various widths and lengths with numerous quantities of each type of pallet. Accordingly, there is an excessive amount of money and storage space tied up in pallets which are on hand solely for a particular size shipping job which may or may not be demanded by a customer.

Some efforts have been made in the prior art to provide adjustability to the material roll packaging systems to reduce this problem. However, these systems lack durability and/or ease of use in the connections used to secure the end plates. As such, the systems are cumbersome and require multiple people working in concert to adjust the components. Further, impacts sustained during the normal shipping process can lead to a failure of the packaging system and damage to the material roll.

Accordingly, it is an object of the present invention to provide an adjustable packaging system for suspending material rolls which is easily adjustable by a single person to accommodate different roll lengths, as well as having sufficiently durable construction and arrangement able to survive normal impacts sustained during shipping.

SUMMARY OF THE INVENTION

The above objectives are accomplished according to the present invention by providing an adjustable suspended roll packaging system comprising a base platform; a plurality of lower rail members are carried by an upper surface of the base platform; a first end plate engages the lower rail members; a second end plate engages the lower rail members in an opposing laterally spaced arrangement with the first end plate; a series of lower positioning teeth are formed in each of the lower rail members; a series of complementary lower connecting teeth are included on each of the first and second end plates engage the lower positioning teeth of the lower rail members securing the first and second end plates to the lower rail members; a plurality of upper rail members are carried by the first and second end plates; a series of upper positioning teeth are formed in each of the upper rail members; a series of complementary upper connecting teeth are included on each of the first and second end plates engaging the upper positioning teeth of the upper rail members securing the first and second end plates to the upper rail members; and, wherein the series of upper and lower connecting teeth provide for the first and second end plates to be repositionable along at least a portion of the upper and lower rail members to adjust the spacing between the first and second end plates.

In a further advantageous embodiment, the upper rail members extend from the first end plate to the second end plate and interconnect an upper edge portion on each of the first and second end plates.

In a further advantageous embodiment, the upper rail members extend parallel with the lower rail members.

In a further advantageous embodiment, the upper positioning teeth on the upper rail members extend along the length of upper rail members from a first distal end portion to a second distal end portion.

In a further advantageous embodiment, a plurality of upper slots are disposed in an upper edge portion on each of the first and second end plates, and the upper connecting teeth disposed in the upper slots, wherein the upper rail members are received in the upper slots so that the upper positioning teeth of the upper rail members engage the upper connecting teeth in the upper slots in interlocking engagement.

In a further advantageous embodiment, the upper rail members include upper positioning teeth disposed on opposite side surfaces, and the upper slots include upper connecting teeth on opposing side surfaces so that a first side surface of the upper slots engage with a first side surface of the upper rail members in interlocking engagement, and a second side surface of the upper slots engage with a second side surface of the upper rail members in interlocking engagement.

In a further advantageous embodiment, the lower rail members extend from the first end plate to the second end plate and interconnect a lower edge portion on each of the first and second end plates.

In a further advantageous embodiment, a notch is included in each lower corner of the first and second end plates receiving the lower rail members, and the lower connecting teeth disposed in the notches engaging the lower positioning teeth of the lower rail members.

In a further advantageous embodiment, the lower positioning teeth on the lower rail members extend along the length of lower rail members from a first distal end portion to a second distal end portion.

In a further advantageous embodiment, a plurality of lower slots are disposed in a lower edge portion on each of the first and second end plates, and the lower connecting teeth disposed in the lower slots, wherein the lower rail members are received in the lower slots so that the lower positioning teeth of the lower rail members engage the lower connecting teeth in the lower slots in interlocking engagement.

In a further advantageous embodiment, the lower rail members include lower positioning teeth disposed on opposite side surfaces, and the lower slots include lower connecting teeth on opposing side surfaces so that a first side surface of the lower slots engage with a first side surface of the lower rail members in interlocking engagement, and a second side surface of the lower slots engage with a second side surface of the lower rail members in interlocking engagement.

In a further advantageous embodiment, a strap slots is disposed in a distal end portion of the lower rail members for receiving a securing strap.

In a further advantageous embodiment, each tooth of the upper and lower connecting teeth and the upper and lower positioning teeth has two inclined engaging surfaces intersecting at a peak in which opposing tooth engaging surfaces are angled at approximately 60 degrees relative to each other.

In a further advantageous embodiment, the series of lower positioning teeth are formed in the upper surface of the base platform. Further, at least one connecting tooth is disposed on a lower edge surface of each the first and second end plates engaging the lower positioning teeth on the base platform in interlocking engagement.

It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can meet certain other objectives. Each objective may not apply equally, in all its respects, to every aspect of this invention. As such, the preceding objects can be viewed in the alternative with respect to any one aspect of this invention. These and other objects and features of the invention will become more fully apparent when the following detailed description is read in conjunction with the accompanying figures and examples. However, it is to be understood that both the foregoing summary of the invention and the following detailed description are of preferred embodiments and not restrictive of the invention or other alternate embodiments of the invention. In particular, while the invention is described herein with reference to specific embodiments, it will be appreciated that the description is illustrative of the invention and is not constructed as limiting of the invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

With reference to the drawings, the invention will now be described in more detail. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are herein described.

Referring toFIGS. 1A-1E, a first embodiment of an adjustable suspended roll packaging system is shown. The packing system includes a base platform, designated generally as10. Base platform10includes a series of base support beams12carrying an arrangement of floor boards14. Preferably, base platform10is arranged to allow for fork lift engagement by including recesses16in base support beams12.

A plurality of lower rail members18are carried on an upper surface20of floor boards14of base platform10. Lower rail members18are secured to upper surface20of base platform10. A series of lower positioning teeth22are formed into each of lower rail members18. In the illustrated embodiment, lower positioning teeth22are define by a series of grooves and ridges formed into lower rail members18and extending along at least a distal end portion22aof each of rail member18. In the embodiment ofFIGS. 1A-1E, lower positioning teeth22are disposed only along an inner side surface23of rail members18.

Referring toFIGS. 1A-1E, a first end plate24and a second end plate26engage both of lower rail members18. First and second end plates24,26are carried in an opposing laterally spaced arrangement. In the illustrated embodiment, first and second end plates24,26are positioned within distal end portion22afor engaging lower positioning teeth22of lower rail members18. An elongated core (not pictured) that carries the material roll (not pictured) is positioned within central opening28in each of opposing end plates24and26to suspend the material over floor boards14.

A series of lower connecting teeth30are included on each of first and second end plates24and26. In the embodiment ofFIGS. 1A-1E, lower connecting teeth30are disposed at the lower corners, designated generally as31, on each of first and second end plates24,26and arranged facing outward toward lower rail members18. Referring toFIG. 1D, a notch, designated generally as33, is carved out of each lower corner31of first and second end plates24,26, which receives lower rail members18. Lower connecting teeth30are recessed in the notches and engage lower positioning teeth22of lower rail members18. In the illustrated embodiment, lower rail members18extend between and interconnect lower corners of opposing first and second end plates24,26.

Referring toFIGS. 5A and 6A, in a further embodiment, an overhang32is formed by each notch in the lower corners31of first and second end plates24,26. In the embodiments shown inFIGS. 5A and 6A, overhang32can be constructed and arranged to engage a top side37of lower rail members18to assist in stabilizing end plates24and26in position relative to lower rail members18.

Referring toFIGS. 1A-1E, lower connecting teeth30are complementary in shape to and adapted for engaging lower positioning teeth22to secure first and second end plates24and26in selected position along distal end portions22aof lower rail members18. Preferably, lower connecting teeth30include a plurality of teeth projected from each lower corner of first and second end plates24and26. However, the arrangement can be accomplished with a single lower connecting tooth on each lower corner of first and second end plates24,26. First and second end plates24and26can be positioned by sliding the end plates vertically downward so that lower connecting teeth30engage with lower positioning teeth22. Accordingly, repositioning first and second end plates24,26simply requires raising the end plates up again, selecting the new position along distal end portions22aof lower rail members18and lowering the end plates back down into interlocking engagement. The interlocking arrangement of the engaging complementary teeth22and30does not require any tools or other connecting members such as screws and the like.

In the illustrated embodiment ofFIGS. 1A-1E, a plurality of upper rail members34are carried by first and second end plates24and26to reinforce an upper edge portion39of first and second end plates24,26. As illustrated, upper rail members34are arranged to extend along the length of base platform10generally parallel with lower rail members18. Upper rail members extend from first end plate24to second end plate26and interconnect upper edge portions39on each of first and second end plates24,26. A series of upper positioning teeth36are formed in each of upper rail members34. As with lower positioning teeth22, upper positioning teeth36are define by a series of grooves and ridges extending along at least a portion of each of upper rail members34. In the illustrate embodiment, upper positioning teeth36are disposed along a distal end portion36ain a complementary arrangement to lower rail members18and lower positioning teeth22.

Each of upper rail members34are received into a respective upper slots38disposed along an upper edge portion39of first and second end plates24and26. A series of complementary upper connecting teeth40are disposed in upper slots38for engaging upper positioning teeth36to secure first and second end plates24and26in position along distal end portion36aof upper rail members34in interlocking engagement.

In the embodiment ofFIGS. 1A-1E, upper positioning teeth36are preferably disposed along both vertical opposite side surfaces of upper rail members34. Upper slots38include complementary upper connecting teeth40on opposing side surfaces so that a first side surface of upper slots38engage with a first side surface of upper rail members34in interlocking engagement, and a second side surface of upper slots38engage with a second side surface of upper rail members34in interlocking engagement.

Upper connecting teeth40are complementary in shape to and adapted for engaging upper positioning teeth36to secure the upper edge portion39of first and second end plates24and26in selected position along distal end portions36aof upper rail members34. Preferably, upper connecting teeth40include at least two teeth projected from vertical opposing side surfaces within each of upper slots38for engaging complementary upper positioning teeth on the vertical side surface of each upper rail member34. First and second end plates24and26can be positioned relative to upper rail members34by sliding rail members34vertically upward out of upper slots38, repositioning first and second end plates relative to lower rail members18as detailed above, and then lowering upper rail members34back into interlocking engagement within upper slots38so that upper connecting teeth40engage with upper positioning teeth36. The interlocking arrangement of the engaging complementary teeth36and40does not require any tools or other connecting members such as screws and the like.

Referring toFIGS. 2A-2C, in this alternative embodiment of the packaging system, lower rail members18include lower positioning teeth22disposed on both vertical side surfaces to increase interlocking engagement with first and second end plates24,26. Accordingly, first and second end plates24and26now each include a plurality of lower slots44along a lower edge portion45for receiving lower rail members18in the same arrangement as upper rail members34are received into upper slots38in the embodiment ofFIGS. 1A-1E.

In the illustrated embodiment ofFIGS. 2A-2C, a series of complementary lower connecting teeth30are disposed on opposing side surfaces of lower slots44for engaging lower positioning teeth22on both sides of lower rail members18to secure first and second end plates24and26in position along lower rail members18. Thus, by engaging both vertical side surfaces of lower rail members18with interlocking teeth, the interlocking engagement is effectively doubled.

Referring toFIG. 2A, in the illustrated embodiment, lower rail members18extend across upper surface20from first end plate24to said second end plate26and interconnect lower edge portion45on each of first and second end plates24,26.

Referring toFIG. 3, an alternative embodiment of the packaging system is illustrated in which lower rail members18are segmented into a plurality of smaller portion for cooperating with first and second end plates24and26in the same interlocking engagement described above in the embodiment ofFIGS. 2A-2C. In the embodiment ofFIG. 3, each of the smaller lower rail members18is secured to base platform10. Lower rail members18again include a series of lower positioning teeth22extending along both vertical side surfaces of each rail member18. In the illustrated embodiment ofFIG. 3, first and second end plates24and26again each include lower slots44along lower edge portions45for receiving lower rail members18in the same arrangement detailed above forFIGS. 2A-2C. A series of complementary lower connecting teeth30are disposed in lower slots44for engaging lower positioning teeth22to secure first and second end plates24and26in position along lower rail members18. Thus, by engaging both vertical side surfaces of lower rail members18with interlocking teeth, the interlocking engagement is effectively doubled, but without lower rail members18extending between first and second end plates24,26along the length of base platform10as may be required to accommodate certain material rolls, as well as reducing some material costs associated with rail members18.

Referring toFIG. 4, this alternative embodiment of the packaging system is shown that is largely similar in arrangement to the embodiment ofFIGS. 2A-2C, with the exception that lower positioning teeth22of lower rail members18and upper positioning teeth36of upper rail members34extended entirely along the length of both vertical side surface on the lower and upper rail members18,34from a first distal end portion to a second distal end portion. Accordingly, upper and lower slots38and44of first and second end plates24and26are repositionable for interlocking engagement at any location along the length of upper and lower rail members34and18to provide maximum flexibility in accommodating various material roll lengths.

Referring toFIGS. 5A-5D, a further embodiment of the packaging system is shown having an arrangement similar to the embodiment ofFIGS. 1A-1E, except that upper rail members34illustrate upper positioning teeth36disposed along a single vertical side surfaces of upper rail members34. As best shown inFIG. 5B, upper slots38of first and second end plates24,26includes complementary upper connecting teeth40disposed on only one side surfaces of the slot for engaging upper positioning teeth36of upper rail members36in interlocking engagement.

Referring toFIG. 5A, lower rail members18engage first and second end plates in the same basic manner as described above forFIGS. 1A-1E. As such, lower connecting teeth30on each of first and second end plates24and are disposed at the lower corners, designated generally as31, and arranged facing outward toward lower rail members18. Notches33receives lower rail members18. Lower connecting teeth30are recessed in the notches and engage lower positioning teeth22of lower rail members18. In the illustrated embodiment, lower rail members18extend between and interconnect lower corners of opposing first and second end plates24,26. Overhang32engages top side37of lower rail members18to assist in stabilizing end plates24and26in position relative to lower rail members18.

Referring toFIGS. 5A and 5C, distal end portions22aof lower rail members18include a strap slot46for receiving a securing strap. Additionally, in the illustrated embodiment ofFIGS. 5A and 5D, a bull nose banding notch48is disposed in distal end portion36aof upper rail members34. Accordingly, a securing strap can be passed though strap slot46in lower rail members18and over upper rail members34at bull nose banding notch48to interconnect upper and lower rail members18,34to resist separation of the rail members from first and second end plates24,26. Securing strap46and bull nose banding notch48can be applied and used in each embodiment detailed herein as desired to improve resilience of the packaging system.

Referring toFIG. 5D, for each of the embodiments detailed herein, each tooth of upper and lower connecting teeth40,30and upper and lower positioning teeth36,22has two inclined engaging surfaces50aand50bintersecting at a peak in which opposing tooth engaging surfaces50aand50bare angled at approximately 60 degrees relative to each other, designated generally as angle “A”.

Referring toFIGS. 6A-6B, a further embodiment of the packaging system is shown having an arrangement similar to the embodiment ofFIGS. 5A-5D, except that lower positioning teeth22are moved from lower rail members18to floor boards14of base platform10. In the illustrated embodiment, a series of lower positioning teeth22are formed in an upper surface of base platform10on floor boards14. At least one connecting tooth30is disposed on a lower edge surface, designated generally as52(FIG. 6B), of each of first and second end plates24,26engaging lower positioning teeth22on floor boards14of base platform10in interlocking engagement.

As noted above, a notch33is included in each lower corner of first and second end plates24,26receiving lower rail members18so that overhang32engages top side37of lower rail members18to assist in stabilizing end plates24and26in position relative to lower rail members18. While no lower positioning teeth22are disposed in notch33for engaging lower rail members18, the arrangements described in the above alternative embodiments for interconnecting first and second end plates24,26with lower rail members18can be used in combination with the arrangement ofFIGS. 6A-6Bin which lower positioning teeth22are included on floor boards14and lower connecting teeth30are also included on lower edge surface52.