Abstract:
A method for storing and/or transporting outboard marine motors utilizes a rack having a rigid, substantially planar, horizontal base with parallel horizontal channels for insertion of fork lift tines. The base supports a pair of upright opposing frames, each frame in turn supporting a respective motor mounting beam. Preferably the frames and base are made of metal, while the motor mounting beams comprise a plywood plank with a metal sheath. At least two outboard motors can be mounted to each beam. Then a forklift is used to lift a fully loaded rack and load it onto a trailer or other carrier vehicle. A multiplicity of loaded racks are transported to a shipping destination. At the shipping destination, the outboard motors are removed from the racks. The empty racks are then returned to the point of origin.

Description:
FIELD OF THE INVENTION 
     This invention relates to systems for storing and transporting outboard motors, and particularly to pallet and rack systems for storing and transporting outboard motors. 
     BACKGROUND OF THE INVENTION 
     Outboard motors for boats and other watercraft are generally packed into corrugated and wood-cleated boxes for storage and transportation from the point of manufacture to a destination, e.g., to a boat building facility or to a boat dealership. This method of packaging is time-consuming, expensive and takes up a great deal of space. In particular, unpacking the outboard motors at their destination involves much labor and the packaging materials are discarded after unpacking, both of which add to the cost of shipping motors. 
     While in the case of a boat dealer, it may be desirable to transport an outboard engine inside its own crate or package to facilitate storage at the boat dealership, this is not true for situations where the outboard engines need not be stored at the destination. For example, if an outboard engine is being shipped to a boat builder who will mount the engine to the boat upon its arrival, there is no need to provide means for protecting the outboard engine during storage. Similarly, if outboard engines are being shipped to a test facility, there is no need for the engines to be packaged or crated. 
     Accordingly, it is desirable to provide a system of storing and transporting outboard motors without crating which utilizes reusable components, is easy to practice and is economic with regard to cost and space requirements. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a rack for storing and transporting outboard motors or engines. In accordance with the preferred embodiment of the invention, an outboard motor rack has a substantially planar base which functions as a pallet by providing a rigid horizontal support structure with tunnels or channels for insertion of forklift arms or tines. The rack further comprises a pair of upright opposing frames secured to the base. Each frame supports a respective motor mounting beam designed to receive a respective plurality of outboard engines mounted thereto, e.g., by means of mountings used to attach outboard motors to boat transoms. Preferably the base and frames are made of metal, while the motor mounting beams can be made of metal, wood, fiberglass, plastic, or any other material having sufficient strength to bear the weight of the motors attached thereto. The preferred material for the motor mounting beams is a plywood beam with a metal L-shaped sheath. The use of plywood has the advantages of reduced cost and easy replacement. 
     The invention is further directed to a method for storing and/or transporting outboard marine motors utilizing a rigid rack having pairs of tunnels or channels for insertion of forklift tines. The base supports a pair of upright opposing frames, each frame in turn supporting a respective motor mounting beam. At least two outboard motors are mounted to each beam. Then a forklift is used to lift a fully loaded rack and load it onto a trailer or other carrier vehicle. A multiplicity of loaded racks are transported to a shipping destination. At the shipping destination, the outboard motors are removed from the racks. The empty racks are then returned to the point of origin. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the outboard motor rack system in accordance with a preferred embodiment of the invention 
     FIGS. 2 and 3 are side and front elevational views, respectively, of the outboard motor rack system in accordance with the preferred embodiment depicted in FIG. 1, with outboard motors (shown in profile) bolted or clamped to the rack for storage and/or transportation. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIG. 1, an outboard motor rack system  10  in accordance with the preferred embodiment of the invention comprises a substantially planar base pallet portion  14  which provides a rigid horizontal support structure. The rack is specifically designed to be lifted by a forklift having a pair of mutually parallel arms or tines at its front end. The base pallet portion  14  is provided with a first pair of channels  30  on one side and a second pair of channels  31  on another side. Although not visible in FIG. 1, the two opposing sides of the base pallet portion  14  respectively have third and fourth pairs of channels. The pair of channels  30  are mutually parallel. Likewise the pair of channels  31  are mutually parallel, but they are generally orthogonal to the pair of channels  30 . The third pair of channels are parallel with the first pair of channels, while the fourth pair of channels are parallel with the second pair of channels. The channels for each pair are preferably separated by the same predetermined distance. The positions of the pair of tines at the front end of a forklift can be The channels for each pair are preferably separated by the same predetermined distance. The positions of the pair of tines at the front end of a forklift can be adjusted to be separated by the same predetermined distance. As a result, a forklift can access the rack from four mutually orthogonal directions. From each direction, the tines of the forklift can be fully inserted into a respective pair of channels and then the rack can be raised by the forklift and loaded onto a trailer, a train car or any other carrier vehicle. 
     In accordance with the preferred embodiment shown in FIG. 1, the rack system further comprises a pair of racks  16  supported on and extending upward from the base portion  14 . Each rack  16  comprises a pair of A-frame structures on opposite sides, each A-frame structure comprising a post  32  and a brace  34 . The posts  32  on opposite sides of each rack are connected by an angled cross member  33 , which is welded to the posts. In addition, each post  32  has a mounting flange  35  with openings for fasteners  50 . Each angled cross member  33  serves as a cradle for a respective motor mounting beam or plank  36 , which is secured to the mounting flanges  35  on opposing sides of each rack by the aforementioned fasteners  50 , which may comprise conventional nut and bolt assemblies. Preferably, the posts  32  of one rack are inclined at an angle of +15 to +25 degrees relative to a vertical plane, while the posts  32  of the other rack are inclined at an angle of −15 to −25 degrees relative to the same vertical plane. Since the plane of the motor mounting beams  36  is generally parallel to the associated posts  32 , the beams  36  lie in the same range of angles. 
     FIG. 1 shows the motor mounting beams  36  fastened by four bolts  50  which penetrate four holes in the mounting flanges  35  and four holes in the beams  36 . However, the elevation of the beams  36  can be increased, for mounting taller outboard motors, by removing the four bolts on each side, raising the beam  36  by an amount equal to the spacing between holes in the mounting flanges  35 , and then fastening the lower three holes on each side of the beam  36  to the upper three holes on each mounting flange  35 . 
     In accordance with the preferred embodiment of the invention, each beam  36  is designed to mimic the shape and dimensions of a boat transom, which allows a respective pair of outboard motors  44  to be mounted to each motor mounting beam  36 , as illustrated in FIGS. 2 and 3, using conventional motor mountings  46  bolted to the motor mounting beams. Alternatively the motor can be clamped to the motor mounting beams. 
     In accordance with the preferred embodiment, each motor mounting beam  36  is constructed as a plywood plank  54  having an L-shaped metal sheath affixed to its top and inner surfaces. A multiplicity of pairs of throughholes  52  are provided in each motor mounting beam  36  for bolting the outboard motors to the beam. In the preferred embodiments, three sets of throughholes, each set comprising two spaced pairs of throughholes are provided in each beam: the sets on the left and right sides are used when two motors are to be mounted on a beam; the set in the middle is used when only one motor is to be mounted on a beam. The middle set of throughholes  52  can be seen in FIG.  3 . Each throughhole  52  penetrates both the metal sheath  56  and the plywood plank  54 . 
     A preferred embodiment of the present invention further comprises a parts storage container  18 , including a removable lid  42 , affixed to the top surface of the base portion  14 . Container  18  is used to transport various small parts and/or accessories which are included with the outboard motors being transported. 
     Referring again to FIG. 1, the base portion  14  preferably comprises a multiplicity of lift tubes  20 ,  20 ′ and  22  each having a rectangular cross section. These lift tubes are interconnected to form a network of communicating tunnels or channels for receiving the tines of a forklift via openings on four sides of the base portion  14 . The lift tubes form a grid or lattice pattern having the general shape of a number symbol (#). Enclosing this grid pattern are a first pair of mutually parallel peripheral supports  24  and a second pair of mutually parallel peripheral supports  26  which form a rectangular periphery. The lattice of lift tubes lies inside this rectangular periphery, with the open ends of the lift tubes communicating with corresponding openings  30  and  31  formed in the exterior sidewalls of the peripheral supports. Preferably the interior sidewalls of the peripheral supports are also provided with openings which are penetrated by the respective lift tube  20  or  22 . The peripheral supports  24 ,  26  are connected at right angles to form corners  28 . Although the lattice of lift tubes can be constructed in many different ways, FIG. 1 depicts the case where a pair of mutually parallel transverse lift tubes  22  extend transversely between opposing peripheral supports  24 ; a first pair of mutually parallel longitudinal lift tubes  20  extend longitudinally between one transverse lift tube  22  and its nearest peripheral support  26 ; a second pair of mutually parallel longitudinal lift tubes  20  extend longitudinally between the other transverse lift tube  22  and its nearest peripheral support  26 ; and a third pair of mutually parallel longitudinal lift tubes  20 ′ extend longitudinally between the transverse lift tubes  22 . Preferably, two pairs of opposing openings are provided in the corresponding sidewalls of each transverse lift tube  22  at the locations where the longitudinal lift tubes intersect the transverse lift tubes, to allow the longitudinal lift tubes  20  and  20 ′ to communicate and be penetrated by forklift tines. 
     The lift tubes  20 ,  20 ′,  22  and the peripheral supports  24 ,  26  are preferably constructed of a rigid, durable high-strength material. In a particularly preferred embodiment of the invention, the lift tubes  20 ,  22  are made from tubular steel having a generally rectangular cross section. The peripheral supports may also be constructed from tubular steel, having a square or rectangular cross section. The lift tubes and peripheral supports may be assembled together by conventional means, for example, by welding of the tubular steel. Such construction allows for a combination of strength and rigidity with a relatively light weight, while allowing penetration of the structural members by the tines of a forklift. It can be readily appreciated that the base portion  14  can be assembled in other ways. For example, the periphery of the base could be formed by connected the ends of adjacent lift tubes with straight peripheral support members between the ends of parallel lift tubes and right-angled peripheral support members at the corners. In other words, each side of the base periphery may comprise a welded assembly of members as opposed to a single unitary member. 
     As previously mentioned, a pair of racks  16  are connected to the base  14 , preferably by welding. Each rack  16  comprises a pair of A-frame structures on opposite sides. Each A-frame structure in turn comprises a post  32  and a brace  34 . The lower end of each post  32  is welded to a peripheral support  24  in the region lying between the channels  31 . The lower end of each brace  34  is welded to a respective corner of the base portion periphery. An upper portion of each post is welded to and supported by the upper end of a respective brace  34 , while opposing posts  32  are connected a respective cross member  40 , as shown in FIG.  1 . The cross members  40  need not be straight. For example, each cross member could have an A-shape. Preferably each side of the rack system, comprising a pair of posts  32  supported by a pair of braces  34 , with the braces being connected by a cross member  40 , and with the lower ends of the posts and braces being welded to a peripheral support  24 , is a planar structure. 
     FIGS. 2 and 3 illustrate a preferred embodiment of the invention wherein outboard motors  44  have been affixed, by means of their standard mountings  46 , to the motor mounting beams  36  of the rack system  10 . It can be readily appreciated that the outboard motor rack system in accordance with the preferred embodiments can carry at least four outboard motors. A larger capacity is possible by extending the length of all transverse elements, including lift tubes  22 , peripheral supports  26  and motor mounting beams  36 , when fabricating the rack system. 
     Additionally, as is best seen in FIG. 2, the motor mounting beams or planks  36  are angled slightly beyond vertical, so that the motors, when mounted thereon, do not extend beyond the external envelope of the two pairs of peripheral supports  24 ,  26 . This prevents the motors mounted thereon from contacting motors on adjacent motor rack systems when several rack systems are placed in close proximity, such as when they are loaded onto trucks for transporting. As shown in FIG. 2, a forklift can engage the rack system  10  from any one of four mutually orthogonal directions by inserting the forklift tines  48  into either the channels  30  which open at the back and front or channels  31  which open on the sides of the base portion. The geometry of the motor rack system protects the mounted motors  44  from being contacted by the front end of the fork lift or adjacent vertical surfaces. This allows for more efficient packing of outboard motors into trailers, with a standard truck trailer being able to accommodate up to nine motor rack systems, each holding four outboard motors, for a total of  36  motors in a single trailer. 
     While the invention has been described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation to the teachings of the invention without departing from the essential scope thereof. For example, channels could be used instead of tubes in the base of the rack for receiving the forklift tines. Also, instead of making the motor mounting beams of wood, metal (e.g., a hollow tube), fiberglass or plastic material could be used. Therefore it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 
     As used in the claims, the term “plurality” means two or more, and the term “beam” includes solid or hollow beams, solid or hollow planks, and equivalent structures.