Abstract:
A rack for securing containers includes a plurality of bays into which one or more containers are received. The rack includes an upper section and a lower section defining a bay therebetween. The bay has a concave support surface for supporting an object. A plurality of columns connect the upper section to the lower section. The upper section and the lower section each include a plurality of complementary interlocking members aligned with the plurality of columns, such that the interlocking members on the upper section would interlock with the interlocking members on the lower section of a similar rack stacked thereon. Each bay may include a resilient member, such as an expandable clamp or a resilient bumper.

Description:
[0001]    This application claims priority to U.S. Provisional Application Ser. No. 60/828,201, filed Oct. 4, 2006 and U.S. provisional Application Ser. No. 60/913,283, filed Apr. 22, 2007. 
     
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates generally to a rack for holding objects and more particularly to a rack for holding water bottles. 
         [0003]    A typical home delivery system for 3 and 5-gallon bottles of drinking water involves a delivery truck, racks, bottles and a driver. The delivery truck is usually configured with several bays on each side with each bay having a rollup door to enclose the product. Inside each bay one or more racks are stored filled with bottles. The racks are typically loaded and unloaded with bottles outside the bays. Fork trucks are used to move the racks in and out of the bays. 
         [0004]    The racks have traditionally been made from metal and more recently from plastic. The plastic racks tend to be modular in design with each component making up a layer of the rack. The layer can hold four bottles in a two by two arrangement or eight bottles in a four wide by two deep arrangement. A two deep arrangement is for 5-gallon bottles whereas 3-gallon bottles will be three deep in the same space. The plastic components can sit on top of an existing pallet for transport or can incorporate runners or blocks into the bottom layer to eliminate the need for a pallet. In either case pallet trucks and jacks are the means for moving the racks. The modular design allows the distributor to stack them to any height but usually three to five layers high. At five layers the rack can hold up to forty 5-gallon bottles. Plastic racks have gained acceptance because they have proven to be more durable and the modular design allows for easy repair. 
         [0005]    Leaking containers are a problem within the existing system. Testing has shown that the bouncing up and down of the bottles in the racks is a significant cause of leaking containers. Whenever the truck is moving the rack and bottles experience vibration and therefore relative movement. The movement at the contact points in combination with other environmental factors such as dirt and dust eventually weakens the bottle resulting in a hole or crack. Testing has shown that the softer plastic racks can reduce this, but a push toward lighter and thinner bottles to reduce costs has made the problem significantly worse in recent years. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention provides a rack for holding objects, such as containers, and more particularly water bottles. 
         [0007]    The rack includes a plurality of bays into which one or more containers are received. Each layer of the rack includes an upper section and a lower section defining a bay therebetween. The bay has a concave support surface for supporting an object. A plurality of columns connect the upper section to the lower section. The upper section and the lower section each include a plurality of complementary interlocking members aligned with the plurality of columns, such that the interlocking members on the upper section would interlock with the interlocking members on the lower section of a similar rack stacked thereon. The interlocking members improve the stability and stacking of layers of the rack. Each bay may include a resilient member, such as an expandable clamp or a resilient bumper. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
           [0009]      FIG. 1  is a perspective view of a rack according to one embodiment of the present invention. 
           [0010]      FIG. 2  is an exploded view of the rack of  FIG. 1 . 
           [0011]      FIG. 2A  is a front view of one of the bays of the rack of  FIG. 1 , partially broken away. 
           [0012]      FIG. 3  is a top perspective view of the layer of  FIG. 1 . 
           [0013]      FIG. 4  is a bottom perspective view of the layer of  FIG. 3 . 
           [0014]      FIG. 5  is a front view of the rack of  FIG. 1 . 
           [0015]      FIG. 5A  is a front view of the rack similar to  FIG. 5 , with a bottle in one of the bays and with an expandable member expanded. 
           [0016]      FIG. 6  is a rear view of the rack of  FIG. 1 . 
           [0017]      FIG. 7  is a side view of the rack of  FIG. 1 . 
           [0018]      FIG. 8  is a perspective view of the rack of  FIG. 1  with a second layer stacked thereon. 
           [0019]      FIG. 9  is a front view of the rack of  FIG. 8   
           [0020]      FIG. 10  illustrates the rack of  FIG. 1  with the pneumatic connections and expandable members for additional layers. 
           [0021]      FIG. 11  is a schematic showing one possible implementation of the rack of  FIG. 8  in a vehicle. 
           [0022]      FIG. 12  is an exploded perspective view of a second embodiment of the rack of the present invention. 
           [0023]      FIG. 13  is a perspective view of an alternative embodiment of the bumper of  FIG. 12 . 
           [0024]      FIG. 14  illustrates the bumper of  FIG. 13  installed in the rack of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0025]      FIG. 1  is a perspective view of a rack  10  according to one embodiment of the present invention. The rack  10  includes a first layer  12  (or first “shelf”) supported on a plurality of supports  14 . The first layer  12  defines a plurality of generally cylindrical bays  16 . A pair of five gallon water bottles (not shown) can be received within each bay  16 . The first layer  12  includes an upper section  22  and a lower section  24 . The lower section  24  includes a partial divider  26  between each adjacent pair of bays  16 . 
         [0026]    The upper section  22  has a plurality (in this example, nine) of column portions  36 , each having a support pad  38  thereon. In this example, the support pads  38  are tapered blocks snap fit to the top of the column portions  36 . The support pads  38  ensure alignment of another layer stacked thereon, although the actual weight is transferred directly to the column portions  36 , not on the support pads  38 . The outer ones of the column portions  36  including a plurality of vertical ribs  37  extending outwardly from a curved inner wall  41 . 
         [0027]    The lower section  24  has a plurality of column portions  44 . The outer ones of the column potions  44  include vertical ribs  45  extending outwardly from a curved inner wall  47 . The upper section  22  also includes a plurality of alignment sleeves  39 , in this example, four alignment sleeves  39  adjacent the corner support pads  38 . 
         [0028]      FIG. 2  is an exploded view of the rack  10  of  FIG. 1 . The support pads  38  can be separately molded pieces, as shown, that can be snap fit onto the upper section  22 . An expandable, inflatable clamping chamber  30  is mounted to the upper section  22  adjacent each bay  16 . The expandable chambers  30  are elongated, flexible pneumatic bladders or seals that extend from the front of the rack  10  to the rear of the rack  10  and curve back to the front of the rack  10  adjacent the adjacent bay  16 . The expandable chambers  30  each include a flange  33  spaced from an integral expandable tubular portion  34 . 
         [0029]    Retainers  31  each include a pair of fingers  32  for locking between the flange  33  and the tubular portion  34  of the expandable chambers  30  to retain the expandable chambers  30  to the upper section  22 , as shown in  FIG. 2A . The upper section  22  also includes a plurality of fingers  35  that protrude between the flange  33  and the tubular portion  34  of the expandable chamber  30  to retain it to the upper section  22 . For installation, the expandable chamber  30  is first routed on the upper section  22 , fitting the flange  33  of the expandable chamber  30  behind the fingers  35 . The retainers  31  are then installed, first fitting the fingers in front of the flange  33  and then snap fitting the retainers  31  to the upper section  22 . If the expandable chamber  30  ever needs to be replaced, the retainers  31  can be removed to remove the expandable chamber  30 . 
         [0030]      FIGS. 3 and 4  are top and bottom perspective views of the layer  12 , respectively. The lower section  24  includes a plurality of alignment recesses  78  aligned with the support pads  38  on the upper section  22  and a plurality of alignment sleeves  76  aligned with the alignment sleeves  39  on the upper section  22 . 
         [0031]      FIG. 5  is a front view of the rack  10  of  FIG. 1 . A partial rear wall  82  prevents bottles from sliding out the back of the bays  16 . The support surfaces  84 , which are the perimeter around the support pads  38 , are recessed relative to the uppermost surface of the upper section  22 . The lowermost surfaces of the walls around the alignment recesses  78  protrude downwardly below a lowermost surface of the lower section  24 . 
         [0032]      FIG. 5A  illustrates the rack  10  of  FIG. 5  with a container, in this example a water bottle  20 , in one of the bays  16 . In  FIG. 5 , the expandable chamber  30  is inflated such that the expandable chamber  30  resiliently clamps the bottle  20  between the expandable chamber  30  and the lower surface of the bay  16 . 
         [0033]      FIG. 6  is a rear view and  FIG. 7  is a side view of the rack of  FIG. 1 . 
         [0034]      FIGS. 8 and 9  illustrate a rack  10 ′ including the rack  10  of  FIG. 1  with a similar second layer  12 ′ stacked thereon. When stacked, the support pads  38  of the lower rack  12  are received in the recesses  78 ′ of the upper rack  12 ′, and the alignment sleeves  76 ′ on the upper rack  12 ′ are received in the alignment sleeves  39  of the lower rack  12  ( FIGS. 3 and 4 ). In this manner, the support pads  38  and recesses  78 ′ are complementary interlocking members, as are the alignment sleeves  39 ,  76 ′. Additionally, the support surfaces  84  of the lower rack  12  contact and support the walls around the alignment recesses  78 ′ below the uppermost surface of the lower rack  12 , which further interlocks the two stacked racks  12 ,  12 ′. All of the weight transfer is through the column portions  36 ,  44 ,  36 ′,  44 ′, not through the alignment sleeves  39 ,  76 ′ and not between the bays  16 ,  16 ′. 
         [0035]      FIG. 10  is a schematic side view of a rack  10  of several layers  12  containing bottles  20  installed in a truck  64 .  FIG. 10  also schematically shows a pump  60  (or compressor), a pressurized tank  61 , a valve  62  and a sensor  63  for actuating the rack  10 . The sensor  63  is installed adjacent the door  66  of the truck  64 . The pump  60  maintains pressure in the tank  61  within a set range in a known manner. The sensor  63  controls the valve  62  (such as a three-way valve) based upon whether the door  66  is opened or closed. The valve  62  vents pressure from the rack  10  when the door  66  is opened and then pressurizes the rack  10  with pressure from the tank  61  when the door  66  is closed. The tank  61  is connected to the rack  10  via conduits  72  each having a quick disconnect  68  formed thereon for connection to a complementary coupling  70  on the rack  10 . Note that a single roll-up door  66  is shown, but one or more swinging doors  66  could also be used. 
         [0036]    In operation, the user loads the bottles  20  into the rack  10  on the truck  64  and then closes the door  66 . Upon detecting that the door  66  is closed, the sensor  63  activates the pump  60  which supplies pressure to the expandable chambers  30  as shown in  FIG. 5A . This locks the bottles  20  in place in the bays  16  in the rack  10 , preventing vibration, damage and movement of the bottles  20  during shipment. When the door  66  is open, the sensor  63  detects the opening of the door  66  and causes the pump  60  to release the air pressure in the expandable chambers  30  which return to the unexpanded. The bottles  20  can then be removed from the bays  16  for delivery. Empty bottles  20  can also be loaded on the rack  10 . When the door  66  is closed again, the expandable chambers  30  are again inflated. Thus, the system is automated and requires no user interaction. 
         [0037]    As a first alternative, the pump  60  could be eliminated. For local delivery trucks, it is possible to store sufficient pressure in the tank  61  for at least one delivery route. The tank  61  would be repressurized when the truck  64  returns to the distribution center to return the empty bottles  20  and pick up more full bottles  20 . 
         [0038]    As a second alternative, the pump  60 , tank  61  and valve  62  could all be eliminated from the truck  64 , if the truck  64  is transporting the bottles  20  from a warehouse to a distribution center, or for some other reason, no bottles  20  will be removed from the racks  10  during transportation. In this situation, the racks  10  can be pressurized at the warehouse before being loaded on the truck  64 . The pressurized racks  10  remain pressurized without any additional outside source of pressure to protect the bottles  20  during shipment and during loading/unloading at the warehouse and distribution center. 
         [0039]    The valve  62  could also be activated based upon a gear/parking brake sensor  65  (or other vehicle operating state) that activates the valve  62  based upon the truck  64  being shifted into and out of a parking gear or based upon the application/release of a parking brake. Therefore, even if the driver forgets to close the door  66 , the racks  10  will be pressurized and the bottles  20  will be locked in place when the parking brake is released and/or when the truck  64  is shifted into gear. Alternatively, a motion or speed sensor could pressurize the racks  10  whenever motion of the vehicle  64  is sensed. 
         [0040]      FIG. 11  is a perspective view of the rack of  FIG. 1  with a pneumatic system for connecting additional layers (not shown), as one implementation of the schematically shown system of  FIG. 10 . The pneumatic system includes a conduit  87  supplying a plurality of branches  86 , which in turn each supply a pair of expandable chambers  30  in each layer. 
         [0041]      FIG. 12  is an exploded view of a rack  110  according to a second embodiment of the present invention. All components are the same as the first embodiment rack  10  except that the expandable chambers  30  are replaced with resilient bumpers  130 . The resilient bumpers  130  in the  FIG. 12  embodiment are actually the same expandable chambers  30  used in  FIGS. 1-11 , but are not connected to any pneumatics and may be sectioned (instead of continuous). Even without being inflated to clamp the bottles, the resilient bumpers  130  provide some cushioning and damping of movement and vibration of the bottles in the bays  16 . 
         [0042]      FIG. 13  illustrates a section of an alternate resilient bumper  230  that could be used in the rack  110  of  FIG. 12 . The resilient bumper  230  includes a pair of flanges  233 ,  234  integral with and connected by a central body portion  235  to form an I-beam cross section. The resilient bumper  230  shown is symmetrical, such that either could be connected to the upper section  22  of the rack  110  ( FIG. 12 ) and either could face the bay  16 ; however, non-symmetrical flanges  233 ,  234  could also be used. 
         [0043]      FIG. 14  illustrates the bumper  230  of  FIG. 13  installed in the rack of  FIG. 1 . The fingers  35 ,  32  are disposed between the flange  233  and the flange  234 . The bumper  230  protrudes into the bay  16  at least partially so that it will be spaced very close to the bottles  20  in order to cushion the bottles  20  and damp the movement of the bottles  20  during vibration or bumps during transportation. In the example shown, less than the thickness of the flange  234  protrudes into the bay  16 , but this can be varied depending upon the dimensions and tolerances of a particular design. 
         [0044]    Although the invention is particularly useful for water bottles  20 , other containers and other objects could be secured in a rack in a similar fashion using the invention described above. Also, the expandable chambers  30  and resilient bumpers  130 ,  230  could be directed upwardly, downwardly, horizontally or diagonally against one or more rows of bottles. The upper and lower sections  22 ,  24  and layers  12  could be molded as one piece, multiple pieces and could optionally snap together. 
         [0045]    In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.