Abstract:
A rampable crate for riding lawn mowers in which a pallet connects to a top frame with a plurality of posts, and the pallet includes a pair of spaced-apart rails disposed at an oblique angle as an upward ramp to an edge of the pallet for travel of the rear wheels of the riding lawn mower with the posts selectively extending from the edge of the pallet to define a downward ramp from the pallet in order for the lawn mower to be driven off the pallet. A method of removing a riding lawn mower from a crate is disclosed.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to crates and methods for storing and shipping heavy durable equipment. More particularly the present invention relates to crates selectively configured for storing and shipping riding lawn mowers and for removing a contained lawn mower by rolling on a ramp extending from the crate and methods for storing riding lawn mowers in crates and removing stored riding lawn mowers from crates. 
       BACKGROUND OF THE INVENTION 
       [0002]    Manufacturers of heavy durable equipment such as lawn mowers, lawn and garden tractors, riding lawn mowers, and the like equipment, package the products in containers for storage and shipping. There are different types of containers used for packaging such equipment including walled cleated containers such as corrugated paperboard wood-cleated containers, and frame-member crates that use wood or steel tube members connected together to form a crate. These containers and crates are referred to generally as containers. Generally, the containers include a pallet, or base, which supports the article within the containers. Posts extend vertically from the pallet and receive or connect to a top frame. The pallet, the posts, and the top frame define a cavity or space which is occupied by the article positioned on the pallet. Some such containers include corrugated paperboard sidewalls or panels. Top flaps foldably attach to the panels to close the open top end of the container. Other of these panel-wall containers use a cap that seats over the upper end of the posts or on the top frame to close the container. 
         [0003]    The containers use the posts to define the interior space to be occupied by the equipment, as well as to communicate top-load compression forces incurred by stacking two or more such containers, for example, in a warehouse for storage or in a truck for shipping. The top frame facilitates the transfer of the top load force through the posts to the pallet. 
         [0004]    While corrugated paperboard wood-cleated crates have been particularly useful for packaging lawn and garden tractors, some manufacturers have preferred to use frame-type packing crates that assemble from elongate wood or steel tube members. Because such crates lack sidewalls, articles held in such frame crates are typically enclosed in plastic sheeting to prevent infiltration of dust and dirt to the equipment. 
         [0005]    At a packing station of a lawn mower manufacturing plant, a finished lawn riding mower is placed on the pallet. This typically involves using an overhead hoist to lift the riding lawn mower over the pallet and then lower the lawn mower onto the pallet. As an alternative, the riding lawn mower could be pushed or driven onto the pallet in the packaging station. It is to be appreciated that wheeled articles placed on pallets of containers can be readily secured to the pallet, such as by straps or connectors, for example, the tie-down device disclosed in U.S. Pat. No. 6,293,398. Articles with spring suspensions particularly can be strapped in place, while riding lawn mowers generally do not require strapping. 
         [0006]    Subsequently, containerized lawn mowers are typically stacked together for storage in warehouses, and for shipping from warehouses to retail outlets. Known crates use a variety of structural elements to facilitate stacking of two crates for handling, storing, and shipping. 
         [0007]    Further, to conserve space and reduce the likelihood of tipping, the center of gravity of the container and the contained equipment should be as low relative to the container. However, the rear wheels of riding lawn mowers typically are larger than the front wheels, and accommodation of differing size wheels on some known pallets may cause the lawn mower to be elevated relative to base members of the pallet that contact a floor or ground. This can result in an elevated center-of-gravity. 
         [0008]    Another problem arises at the retail sales center for the lawn mower. The lawn mower must be removed from the crate for display and sale. Pushing lawn mowers from the pallet requires participation of several persons, particularly if the wheels are chocked by transverse members in the pallet. 
         [0009]    Accordingly, there is a need in the art for an improved crate for storing, handling, and shipping of riding lawn mowers to have a low center of gravity yet providing structure for readily removing the riding lawn mower from the crate. It is to such that the present invention is directed. 
       SUMMARY OF THE INVENTION 
       [0010]    The present invention meets the needs in the art by providing an improved rampable crate for storing, handling, and shipping riding lawn mowers. In one aspect, the present invention provides a rampable crate for riding lawn mowers, comprising a pallet configured for supporting a riding lawn mower and with a top frame connected by a plurality of posts extending between the pallet and the top frame so that the assembled structure defines a cavity therebetween for holding the riding lawn mower. The pallet includes a pair of spaced-apart rails each oriented at an oblique angle relative to a longitudinal axis of the pallet, with a first end of the rail attached to a first transverse member of the pallet and an opposing second end of the rail attached to a transverse end member of the pallet, the first end vertically spaced below the vertical spacing of the second end relative to the pallet. The rails define an angled ramp upwardly towards the transverse end member and the posts being selectively disposed below the transverse end member and extending laterally therefrom define a downward ramp from the pallet in order for the lawn mower to be driven from the pallet. 
         [0011]    In another aspect, the present invention provides a method of containerizing a riding lawn mower in a rampable crate for storage and for removal therefrom, comprising the steps of: 
         [0012]    (a) placing a riding lawn mower on a pallet, the pallet including a pair of spaced-apart rails each oriented at an oblique angle relative to a longitudinal axis of the pallet, with a first end of the rail attached to a first transverse member of the pallet and an opposing second end of the rail attached to an end transverse member of the pallet, the first end vertically spaced below the vertical spacing of the second end relative to the pallet, with the rails aligned with a respective one of the wheels of the riding lawn mower; 
         [0013]    (b) positioning a top frame on a plurality of posts extending from the pallet to containerize the riding lawn mower therein; 
         [0014]    (c) shipping the containerized riding lawn mower to a sales location; 
         [0015]    (d) removing the posts and positioning the posts at an oblique angle extending outwardly and downwardly from the pallet; and 
         [0016]    (e) driving the riding lawn mower from the pallet, the rails define an angled ramp upwardly towards the end transverse member and the posts define a downward ramp from the pallet in order for the lawn mower to be driven off of the pallet. 
         [0017]    Other objects, advantages, and features of the present invention will become readily apparent upon reading the following detailed description in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  illustrates in exploded perspective view a crate for riding lawn mowers according to the present invention. 
           [0019]      FIG. 2  illustrates a detailed side view of the pallet of the crate for riding lawn mowers illustrated in  FIG. 1 . 
           [0020]      FIG. 3  illustrates in perspective view the crate illustrated in  FIG. 1  with posts of the crate disposed for a ramp prior to roll off of the riding lawn mower from the pallet. 
           [0021]      FIG. 4  illustrates in perspective view the crate with the front wheels of the riding lawn mower rolling over an upper transverse member of the pallet. 
           [0022]      FIG. 5  illustrates in perspective view the riding lawn mower with the front wheels rolling down the ramp formed by the posts and the rear wheels rolling upwardly on a inclined member of the pallet, so that the blade housing of the riding lawn mower moves freely over the upper transverse member of the pallet. 
           [0023]      FIG. 6  illustrates in perspective view the riding lawn mower removed from the crate with the rear wheels rolling down the ramp formed by the posts. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    With reference to the drawings in which like parts have like reference numerals,  FIG. 1  illustrates in exploded perspective view a rampable crate  10  having a pallet generally  12  and opposing top frame  14  and vertical posts  16 . The pallet  12  interlinks to the top frame  14  by the posts  16  to define an interior cavity generally  18  for holding an article such as a riding lawn mower  19  for storage, handling, and shipping. The riding lawn mower  19  includes a blade housing  21 . 
         [0025]    The pallet  12  includes a pair of elongated longitudinal outside members  20  and a pair of spaced-apart interior longitudinal members  22 . Receiving sockets  24  attach to distal ends of the outside members  20 . A lower end of the receiving socket  24  connects to a respective distal end of a lower transverse end member  26  extending between the outside members  20 . An upper transverse end member  28  extends between opposing receiving sockets  24 . The upper transverse end member  28  is spaced-apart from the lower transverse end member  26  to define a gap  30 . The pallet can use two separate upper transverse end members as illustrated on the opposing end. 
         [0026]    A forward transverse member  32  extends between the opposing outside members  20  and is spaced-apart from the transverse end member  26 . A rear transverse member  34  also extends between the outside members  20  and is spaced-apart from the front transverse member  32 . A pair of elongate interior ramp members or rails  36  connect between the upper surface of the upper transverse end member  28  and the rear transverse member  34 . As best shown in side detail view in  FIG. 2 , this disposes the interior ramp members  36  at an oblique angle relative to a plane defined by the lower surfaces of the lower transverse end members  26 , the front transverse member  32 , and the rear transverse member  34 . The interior ramp members  36  have first ends  38  connected to the lower transverse end member  26  and opposing second ends  40  connected to the rear transverse member  34 . The first ends  38  are thereby spaced vertically higher than the opposing second ends  40 , for a purpose discussed below. 
         [0027]    With continuing reference to  FIG. 1 , chock members  42  connect between the lower transverse end member  26  and the front transverse member  32 . The chock members  42  are disposed intermediate the respective interior ramp member  36  and the interior longitudinal member  22 . Each chock member  42  and the adjacent interior ramp member  36  define a receiving space generally  44  for receiving a front wheel of the riding lawn mower  19  when seated on the pallet  12 . The spacing depends upon the width of the front wheel of the riding lawn mower to be contained within the crate  10 . 
         [0028]    The interior ramp members  36  are spaced from the outside members  20  to align with the rear wheels of the riding lawn mower. A rear wheel chock member  46  extends between the outside members  20  and attaches to upper surfaces of the members  20  and the interior members  22 . The rear chock member  46  and the rear transverse member  34  cooperatively define spaces  48  for seating of the rear wheels of the riding lawn mower on the pallet  12 . 
         [0029]    In the illustrated embodiment, support blocks  50  attach to respective distal ends of the outside members  20  adjacent respective distal ends of the lower transverse end members  26 . 
         [0030]    The top frame  14  includes opposing longitudinal members  62  joined at distal ends to opposing transverse end members  66 , such as with one of a projecting corner lug  64 . An intermediate transverse member  68  extends between the members  62 . A pair of projecting members  70  attach to inward faces of the end members  66  and spaced-apart from the corner lugs  64 . In the illustrated embodiment, the projections  70  are inverted V-shaped members formed by cutting and bending a steel rod. 
         [0031]    Posts  16  extend between the pallet  12  and the top frame  14  when assembled to containerize an article held on the pallet  12 . In the illustrated embodiment, the post  16  is sized for a lower end being received in the socket  24  of the pallet  12  while the opposing end of the posts receives the lug  64  projecting from the top frame  14 . It is to be appreciated that other structures similarly interlock posts with sockets on pallets and top frames to form an assembled container  10  that defines the interior space  18  that receives the article held on the pallet  12 . Further, the posts  16  are readily selected from posts of differing lengths, so that a group of posts in which the posts have a first length accommodate a riding lawn mover with a first vertical height, while a second group of posts have a second length to accommodate a riding lawn mower with a second vertical height. 
         [0032]    The pallet  12  and the top frame  14  are readily assembled with elongated steel tubes welded together rigidly, or other suitable rigid members. The posts  16  also are elongated steel tubes or other suitable rigid members. 
         [0033]    At a packing station, a finished lawn riding mower is placed on the pallet  12 , for example, by using an overhead hoist, pushing the riding lawn mower onto the pallet, or other mover for seating the riding lawn mower on the pallet. The wheels are received in the respective front wheel wells  44  and rear wheel wells  48 . The wheel chocks  42 ,  46  keep the riding lawn mower from forward and rearward movement and lateral movement. It is to be appreciated that wheeled articles placed on pallets of containers can be readily secured to the pallet, but riding lawn mowers lacking spring suspensions generally do not require such securing. 
         [0034]    Two or more assembled containers readily stack together (not illustrated) for handling, storing, and shipping purposes. Stacking is accomplished by lifting a second one of the crates  10  and placing the second crate on top of a first one of the crates. An inner surface of the lower transverse end member  26  of the second crate  10  bears against the projecting members  70  of the top frame  14  of the first crate. The mass of the crate and its contents, cooperatively with the projecting members  70 , hold the crates stacked together in routine stacking, handling, and shipping. The block  50  can abut against a side portion of a respective one of the projecting members  70 . Alternate structures for stacking include attaching a plurality of projecting lugs that extend upwardly from the top frame and providing the pallet with shoes or receivers. The shoes of an upper crate align with the lugs of a lower crate. In an alternate structure, walled targets known in the trade extend upwardly from the top frame and a plurality of feet or stubs extend downwardly from the pallet. The targets of a lower crate receive a respective foot of an upper crate. 
         [0035]      FIGS. 3-6  illustrate the operation of the crate  10  for removal of the riding lawn mower  19 , such as at a retail distribution center.  FIG. 3  illustrates in perspective view the crate  10  with the top frame  14  and the posts  16  removed prior to roll out of the riding lawn mower  19  from the pallet  12 . The posts  16  insert into the gap  30  between the lower and upper transverse end members  26 ,  28  and on opposing sides of the respective interior ramp member  36 . The posts  16  extend outwardly from the pallet  12  substantially parallel to a vertical plane defined by the interior ramp member  36 . The posts  16  slope at an oblique angle relative to the ground downwardly from the lower transverse end member  26  to the ground. 
         [0036]      FIG. 4  illustrates in perspective view the crate  10  with the front wheels of the riding lawn mower  19  rolling over the upper transverse member  28  of the pallet  12 . This is accomplished a driver starting the riding lawn mower  19  and engaging the transmission to propel the riding lawn mower forwardly. Alternative, the riding lawn mower can be pushed from the pallet  12 . The front wheels move out of the chocked space  44 , on to the upper transverse end member  28 , and then onto the ramp defined by the posts  16 . 
         [0037]      FIG. 5  illustrates in perspective view the riding lawn mower  19  with the front wheels rolling down the ramp formed by the posts  12  and the rear wheels rolling upwardly from the space  48  on the inclined interior ramp member  36  of the pallet  12 . With the front end of the riding lawn mower  19  moving downwardly on the outer ramp of the posts  16  and the back end of the riding lawn mower moving upwardly on the interior ramp member  36 , the blade housing  21  of the riding lawn mower passes over the upper transverse member  28  freely. As noted above, the interior ramp member  36  is disposed centered relative to the rear tire, so that the tire of the rear wheels rolls on the ramp member as the riding lawn mower moves forwardly. As the riding lawn mower continues its forward movement, the rear wheels then contact and move over the upper transverse end member  28 , and then on to the ramp formed by the posts  16 . 
         [0038]      FIG. 6  illustrates in perspective view the riding lawn mower  19  removed from the crate  10  with the rear wheels rolling down the ramp formed by the posts  16 . After moving the riding lawn mower off of the ramp formed by the posts  16 , the pallet  12 , the top frame  14 , and the posts  16  can be disposed of, for example, for recycling of the metal tube members or return to the manufacturer for re-use of the crate. 
         [0039]    While this invention has been described in detail with particular reference to an illustrated embodiment thereof providing a crate configured readily for storing, handling, and shipping of riding lawn mowers and for removing the contained riding lawn mower therefrom, it should be understood that many modifications, additions and deletions, in additions to those expressly recited, may be made thereto without departure from the spirit and scope of the invention as set forth in the appended claims.