Abstract:
During shipping, it is not uncommon to have loads shift in transit. To help alleviate this problem, a portable bulkhead or spacing system is provided. The system is nestable for easy storage, lightweight, durable, and cost effective. The combination of these factors, thus, allows for shipping efficiencies to drastically increase so that products can be effectively shipped resulting in an overall lower cost to the consumer and generating an advantage over competition.

Description:
CLAIM OF PRIORITY 
     This application claims priority to U.S. Provisional Application No. 60/709,063, entitled “A PORTABLE SPACING MEMBER” filed on Aug. 17, 2005, which is hereby incorporated by reference for all purposes. 
    
    
     TECHNICAL FIELD 
     The invention relates generally to a portable bulkhead system and, more particularly, to a nestable, lightweight, and storable spacing system. 
     BACKGROUND OF THE INVENTION 
     Oftentimes during shipping, cargo included within a shipping container, such as a trailer, does not consume the entire volume of the container. Having empty space within shipping containers can be a significant problem in that shipping containers are in motion, with almost continuous stopping, starting, and changing directions. These accelerations can, thus, cause the cargo within the shipping containers to shift in transit. This inadvertent shifting of cargo can cause severe damage to the cargo being shipped, especially if the cargo is fragile, like glass products. However, the inclusion of heavy volumetric spacing members are not particularly practical because storage of the spacing members can be difficult and because the cost of shipping can be substantially increased due to the weight of the spacers. Therefore, there is a need for a method and/or apparatus for a lightweight and portable spacing member system that assists in preventing shifting of cargo within a shipping container in transit. 
     SUMMARY 
     The present invention, accordingly, provides a system for spacing comprising at least one pair of parallel planar members having a plurality of interlocking pairs of substantially hollow members of a selected shape extending therebetween to maintain a selected distance between the planar members. 
     In another preferred embodiment of the present invention, there are a plurality of spacing members. Each spacing member comprises a planar member having a first side and an opposite second side. Additionally, each spacing member comprises a plurality of frustums extending from the first side of the planar member and terminating at an upper plane that is substantially parallel to the planar member, wherein each frustum includes at least one slot formed in an upper surface bordered by the upper plane. 
     In yet another preferred embodiment of the present invention, the hollow members are substantially conical frustums, and another preferred embodiment includes or comprises frustums that have a corrugated frustoconical surface. 
     An alternative, preferred embodiment of the present invention is a system comprising at least one pair of spacing members that face one another. Each spacing member includes or comprises a planar member having a first side and an opposite second side. Additionally, each spacing member comprises a plurality of frustums extending from the first side of the planar member and terminating at an upper plane that is substantially parallel to the planar member, wherein each frustum includes at least one slot formed in an upper surface bordered by the upper plane. 
     In yet another alternative preferred embodiment, a spacing member is provided. In the spacing member, there is a planar member having a first side and an opposite second side. Additionally, there is a plurality of frustums extending from the first side of the planar member and terminating at an upper plane that is substantially parallel to the planar member, wherein each frustum includes at least one slot formed in an upper surface bordered by the upper plane. 
     The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is an isometric view of a spacing member embodying features of the present invention; 
         FIG. 2  is a top view of the spacing member of  FIG. 1 ; 
         FIG. 3  is a side view of the spacing member of  FIG. 1 ; 
         FIG. 4  is a front view of the spacing member of  FIG. 1 ; and 
         FIG. 5  is a side view of spacing members of  FIG. 1  in an operative position. 
     
    
    
     DETAILED DESCRIPTION 
     Refer now to the drawings wherein depicted elements are, for the sake of clarity, not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views. 
     Referring to  FIGS. 1-4  of the drawings, the reference numeral  100  generally designates a spacing member embodying features of the present invention. The spacing member  100  comprises a planar member  102 , conical frustums  104 , frustoconical surfaces  106 , corrugations  108 , slots  110 , and a cross member  112 . 
     In normal shipping operations, palletized loads are often placed within the shipping containers. Various types of cargo and products are secured to pallets for easy loading and unloading of the cargo. Oftentimes these palletized loads can also be very heavy, potentially weighing in excess of 1 ton. These palletized loads, though, are not immune from shifting, even though they may be heavy. 
     To combat the problems of motion during shipping, the spacing member  100  is employed. The spacing member  100  can operate alone or in combination with other spacing members  100  to form bulkheads. Additionally, the spacing member  100  is typically made of a lightweight material, such as certain plastics or polymers like a high density polyethylene. By utilizing lightweight materials, the spacing members  100  can be easily manufactured at very low costs through techniques like injection molding or vacuum forming. For use with shipping applications, the spacing members  100  measure about 48.375 inches by about 36.375 inches by about 16.5 inches. Typically, these spacing members  100  are thermoformed from a high density polyethylene sheet having an approximate thickness of 0.390 inches prior to thermoforming, weighing about 26.5 pounds. 
     As can be seen in  FIGS. 1-4 , the base of the spacing member  100  is a planar member  102 . This planar member  102  is typically corrugated to provide additional strength and resistance to compressive and torsional loads. The planar member  102 , though, by itself, does not provide sufficient volume to resist the motion of cargo. According to a preferred embodiment of the present invention, hollow structures (conical frustums  104 ) are formed through the techniques like thermoforming in the planar member  102 . 
     The use of the structures protruding from the planar member  102  allow for an expansive volume of the spacing member  100 . As shown in  FIGS. 1-4 , extending in a direction away from the planar member  102  are a plurality of conical frustums  104  that are reinforced by cross members  112  that interconnect the plurality of conical frustums  104 . Each of the conical frustums  104  narrows as a function of the distance from the planar member  102 , and each of the conical frustums  104  terminates at a relatively uniform distance from the planar member  102 . In other words, each of the conical frustums  104  terminates at a plane that is approximately parallel to the planar member  102 . In the case where hollow structures protrude from both sides of the planar member  102 , two approximately parallel planes can be utilized to illustrate termination of the conical frustums  104 . Moreover, it is also possible to have conical frustums terminate at different relative distances to yield either a staggered or stepped configuration. Furthermore, any of the planes can be at an angle to the planar member  102  in other embodiments. 
     As can also be seen in  FIGS. 1-4 , the conical frustums  104  include a frustoconical surface  106  that is non-uniform. In particular, corrugations  108  are included within each frustoconical surface  106 . The inclusion of the corrugations  108  within each frustoconical surface  106  allows for increased strength and rigidity. Typically, the corrugations  108  run in a direction orthogonal to the planar member  102  along the entire frustoconical surface  106 . Moreover, the use of the corrugations  108  is not limited to frustoconical surfaces  106 , but can also be employed on the surface of any other shape utilized. 
     At the plane where the conical frustums  104  terminate, slots  110  are located within each of the conical frustums  104 . Typically, these slots  110  are symmetrically arranged in a manner such that the slots  110  are able to receive a corresponding and complementary conical frustum  104  of another spacing member  100  in a face-to-face configuration, as shown in  FIG. 5 . In particular, slots  110  allow for the complementary spacing members  100 , shown in  FIG. 5 , to lock with one another. 
     When placed within a bulkhead or in a storage container, the combination of the structure and materials used provide a number of advantageous qualities. In particular, spacer member  100  combined into a system, as shown in  FIG. 5 , can withstand a very large load, typically compressive loads, across the planar member  102  in excess of 21,000 pounds. Additionally, the spacer member is designed so as to have a small amount of compressive deflection, typically no more than 2.5 inches. A spacer member  100  may also function as a single unit with a plastic or fiber separator pad positioned to face the conical frustums  104  and compressed against the shipping container wall. Two or more pairs of spacing members  100  can also be used with one another in combination. 
     Since the spacing members  100  engage one another to lock in a face-to-face configuration, there are several other additional advantages. Specifically, this locking feature can be bi-directional, making part orientation irrelevant. Moreover, the locking feature can be adjusted so as to be implemented under various loads, for example with no more than 150 pounds static load and no less than 50 pounds static load placed over any corner of the pair of spacing members  100 . 
     Moreover, because the conical frustums  104  are hollow, the interiors of the conical frustums  104  are accessible through openings (not shown) within the planar member  102 . These openings (not shown) allow for the spacing members  100  to be stacked on top of one another. This stackability or nestability reduces the amount of space required for storing the spacing members when not in use. Anti-jam ledges (not shown) can also be located within the conical frustrums to assure ease of denesting. Moreover, individual or nested bulkhead stacks can be accessed and maneuvered by forklift on two flat ledges between the three conical frustums  104 . Another advantage is that rotation of one spacer on top or beneath (180 degrees) should produce a vertical gap between bulkhead parts to enable separation and lift by fork truck blades. 
     Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered obvious and desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.