Abstract:
A container for stackable articles includes a base assembly, a plurality of side assemblies, a 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 members with a plurality of bearing portions adjacent and integral to each shelf support member. A plurality of shelf members are provided, wherein each shelf member is fixed about a respective bearing portion at each end of the shelf assembly. The shelf assemblies are secured to the sidewall assemblies, and positioned in the storage space to engage manufactured articles, for example sunroofs, positioned therein.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application Ser. No. 60/812,906 having a filing date of Jun. 12, 2006. 
     
    
     TECHNICAL FIELD  
       [0002]     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  
       [0003]     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.  
         [0004]     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, a 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.  
         [0005]     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  
       [0006]     In one aspect, the present invention provides a container for shipping and storing manufactured articles. The container includes a container body with a base assembly and a plurality of walls. Each of the walls includes a lower edge attached to the base assembly and at least one lateral edge joined to an adjacent wall panel. At least one shelf assembly, and preferably a plurality of shelf assemblies, is also provided which are secured to the wall assemblies and protrude into an interior of the container body. A first shelf assembly includes a first shelf support member and a second shelf support member for structural support of the shelf assembly. Each shelf support member includes at least a first block portion or shelf bearing portion, and a second block portion or shelf bearing portion integral thereto, wherein the first and second block portions together define a first recessed slot or notch therebetween. At least one shelf member extends between the first and second shelf support members, thereby forming a shelf extending substantially across the interior of the container. A preferred embodiment includes two shelf assemblies containing more than two block portions, thereby accommodating a plurality of shelf members.  
         [0007]     Stated another way, the present invention includes a container including at least one shelf assembly and preferably a plurality of shelf assemblies. Each shelf assembly includes a first shelf support member containing a first plurality of adjacent and integral block portions and a second shelf support member containing a second plurality of adjacent and integral block portions. Each one of the second plurality of block portions corresponds to one of the first plurality of block portions. A first plurality of slots is contained within the first shelf support member wherein each slot is defined between two sequential or adjacent block portions of said first plurality of block portions for support of a shelving member described below. A second plurality of slots is contained within the second shelf support member wherein each slot is defined between two sequential or adjacent block portions of said first plurality of block portions for support of a shelving member described below. A first plurality of shelf members is provided wherein each shelf member includes a first tab, a second tab, a third tab, and an aperture, wherein each first tab is fixed within a respective one of the first plurality of slots, each second tab is fixed within a respective one of the second plurality of slots, and each third tab mates with an aperture of an adjacent shelf member.  
         [0008]     Other shelf assemblies may be formed in the same manner and employed within the interior of the shipping container. In general, containers formed in accordance with the present invention will preferably contain two shelf assemblies on opposite sides of the shipping container interior. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is a partial exploded view of one embodiment in accordance with the present invention;  
         [0010]      FIG. 2  is a partial exploded view of one embodiment in accordance with the present invention;  
         [0011]      FIG. 3  is a partial exploded view of one embodiment in accordance with the present invention;  
         [0012]      FIG. 4  is an exploded view of the shelf assemblies in accordance with the present invention;  
         [0013]      FIG. 5  is an exploded view of the shelf assemblies in conjunction with the wall assemblies;  
         [0014]      FIG. 6  is a plan view of a laminate of multiple layers of corrugated material for forming shelf support members in accordance with the present invention.  
         [0015]      FIG. 7  is a perspective view of a shelf support member in accordance with the present invention;  
         [0016]      FIG. 8  is a plan view of a shelf member in accordance with the present invention;  
         [0017]      FIG. 9  is a partial exploded view of one embodiment in accordance with the present invention;  
         [0018]      FIG. 10  is a partial exploded view of one embodiment in accordance with the present invention;  
         [0019]      FIG. 11  is a partial exploded view of one embodiment in accordance with the present invention;  
         [0020]      FIG. 12  is a partial exploded view of one embodiment in accordance with the present invention;  
         [0021]      FIG. 13  is an exploded view of one container in accordance with the present invention; and  
         [0022]      FIG. 14  is a partial exploded view of one embodiment in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0023]      FIGS. 1-14  illustrate one embodiment of a container  10  for 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.  
         [0024]      FIG. 1  illustrates a base  12  of the container  10 . Base  12  comprises a frame portion  12   a  (for example, a corrugated laminate pallet, or a wooden shipping pallet) and a container bottom portion  12   b . Bottom portion  12   b  has a body  12   c  and a plurality of flaps  12   d  formed along edges of body  12   c . Bottom portion  12   b  may also be formed from a sheet of corrugated material cut to form flaps  12   d , 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 portion  12   a.    
         [0025]     Referring to  FIG. 2 , a body portion  14  is positioned and secured within base portion  12 . Body portion  14  has a rear wall portion  14   a  and a plurality of side flaps  14   b  and base flaps  14   c  formed along edges of rear wall portion  14   a . Body portion  14  may be formed from a sheet of corrugated material cut to form side flaps  14   b  and base flaps  14   c  which are then folded as shown and secured to base portion body  12   c  and to base portion flaps  12   d.    
         [0026]     Referring to  FIG. 3 , a rear stop portion  16  is secured to rear wall portion  14   a  to provide a cushion or shock absorbing member for articles inserted into and stored in container  10 . Rear stop portion  16  may also occupy dead space between rear wall portion  14   a  and edges of the components stored in the container, thereby aiding in immobilization of the components stored in the container. Rear stop portion  16  may be formed from a sheet of corrugated material cut to size and folded as shown to produce a shock-absorbing wedge  16   a  therein. The rear stop portion is then positioned and secured to rear wall portion  14   a  of body portion  14 . Alternatively, foam or other padding may be secured to rear wall portion  14   a  of body portion  14  to provide the desired cushioning effect.  
         [0027]     Referring to  FIGS. 5-8 , a left wall  20  and right wall  22  of the container are provided for supporting the components to be stored and shipped in the container. Walls  20 ,  22  each include respective wall portions  20   a ,  22   a , a plurality of shelf support portions  24  secured to wall portions  20   a ,  22   a , and a plurality of shelf portions  18  secured to wall portions  20   a ,  22   a  and supported by shelf support portions  24 .  
         [0028]      FIG. 6  is a plan view of a laminate of multiple layers of corrugated material for use in forming shelf support portions  24  of the present invention, shown prior to cutting of the shelf support portions.  FIG. 7  is a perspective view showing a laminated shelf support portion  24  of the container  10  of the present invention cut to shape. Referring to  FIGS. 6 and 7 , shelf support members or portions  24  may be produced by forming a laminate of multiple layers of corrugated material and die-cutting or otherwise cutting the laminate to the achieve the desired profile or shape shown in  FIG. 7 . For example, using the laminate arrangement of  FIG. 6 , eight shelf support portions may be cut from a single laminate.  
         [0029]     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 in  FIGS. 6 and 7 , in one embodiment, shelf support portions  24  includes a plurality of bearing portions  24   a , with a slot  24   b  formed between adjacent ones of bearing portions  24   a . In the embodiment shown, bearing portions 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. Slots  24   b  are dimensioned (in conjunction with tabs  18   f  on shelf portions  18 , described in greater detail below) so as to provide an interference fit with tabs  18   f  inserted therein, thereby providing additional structural stability to the container.  
         [0030]     Referring to  FIG. 8 , shelf portions  18  are provided which span a distance between adjacent shelf support portions  24 , thereby providing substantially continuous support of the stored components along the lengths thereof when they are positioned and secured within the container. Shelf portions  18  may be formed as shown in  FIG. 8 , wherein one or more sheets of corrugated material are cut to the shape shown an then cut down the center thereof (along line  18   a ) to form two shelf members  18 .  
         [0031]     In one method of assembly of walls  20 ,  22 , shelf portions  18  are folded along folds  18   b  and  18   c  ( FIG. 8 ), to substantially conform to the profile of bearing portions  24   a  ( FIGS. 6 and 7 ) of shelf support portions  24 . Successive ones of shelf members  18  are then connected or daisy-chained together by fixing or inserting tab  18   d  from one shelf portion  18  into slot or aperture  18   e  of an adjacent shelf portion  18 , thereby creating a continuous, accordion-like shelf structure. “Fixing” may mean simply inserting the tab or flap  18   d  into the corresponding aperture  18   e  of the next adjacent shelf member  18 . Or, “fixing” may mean to glue or otherwise ensure that flap  18   d  is snugly fit within aperture  18   e  of the subsequent or adjacent shelf member  18 . This shelf structure may be easily positioned to follow the contours defined by shelf support bearing portions  24   a , by bending tabs  18   f  out of the plane of the shelf section on which they are formed, and inserting tabs  18   f  into corresponding slots  24   b  formed or defined between adjacent bearing portions  24   a  of shelf support portions  24 . Tabs  18   f  are formed in positions along shelf portions  18  such that insertion of the tabs into slots  24   b  forces the shelf portion structure to bend according to the contours of the shelf support portion. When all of tabs  18   f  have been inserted into associated slots  24   b , the tabs are bent back into the plane in which they were originally formed, during which a formed end of each shelf portion  18  wraps over a corresponding surface of a bearing member  24   a  of shelf support portion  24 . Shelf portions  18  are now supported at each end thereof by a bearing portion  24   a . Shelf support portions  24  may then be positioned along wall portions  20   a ,  22   a  and glued or otherwise secured to the wall portions.  
         [0032]     Other assembly methods or sequences are also contemplated. For example, shelf support portions  24  may be secured to wall portions  20   a ,  22   a  prior to attachment of shelf portions  18  thereto. When walls  20 ,  22  are complete, each wall is secured to a corresponding side flap  14   b  of body portion  14 .  
         [0033]      FIG. 14  shows a front  30  of the container. Front  30  comprises a body  30   a  and a plurality of flaps  30   b  formed along edges of body  30   a . Front  30  may be formed from a sheet of corrugated material cut to form flaps  30   b , which are then folded and secured to each other as shown so as to wrap over edges of walls  20 ,  22 . A shock absorbing positioning member such as rear stop portion or a foam padding, similar to that provided along rear wall  14   a , may be secured to an interior surface of front  30 .  
         [0034]      FIG. 9  shows a top  32  of the container. Top  32  comprises a body  32   a  and a plurality of flaps  32   b  formed along edges of body  32   a . Top  32  may be formed from a sheet of corrugated material cut to form flaps  32   b , which are then folded and secured to each other as shown to form a top which may be wrapped over upper edges of walls  20 ,  22  and body portion  12 .  
         [0035]      FIGS. 10-13  show various stages in the final assembly of the shipping container  10 .  
         [0036]     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.