Abstract:
A forkstrap connector for removably connecting individual forkstraps or a forkstrap unit to a shipping container, said forkstrap connector including plurality of barbs for engaging the forkstraps of forkstrap unit and a shipping container utilizing at least one forkstrap connector.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 61/822,543 filed on 13 May 2013, which is hereby incorporated by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable 
       REFERENCE TO A “MICROFICHE APPENDIX” 
       [0003]    Not applicable 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    The present invention generally relates to returnable shipping containers, and more specifically to shipping containers having replaceable forkstraps or a replaceable forkstrap unit. 
         [0006]    2. General Background of the Invention 
         [0007]    For many years, industries dealing in bulk goods have utilized returnable containers. A common problem is that containers have to be scrapped at great cost due to damage to the forkstraps many other containers must be scrapped because all or a portion of the connector used to join the forkstraps to the base is formed integrally with the base, rendering the base unusable if even a single connector is damaged. 
         [0008]    Additional issues arise due to the fact that known integral connectors rely on interlocking connections that, as a practical matter, make them extremely difficult to remove. The reason for this is that a forkstrap must be retained with sufficient force that it will not inadvertently disconnect under normal use conditions. Thus, the forkstrap must be able to resist a separating force applied to even if more than one loaded container being carried on tips to one side, and such containers often carry 2000 pounds in bulk goods in addition to the weight of the container. Accordingly, as a practical matter, many users will scrap a container with a damaged forkstrap, even if the forkstrap is theoretically replaceable, because the force required to remove the forkstrap often damages the base or the integral connectors or both (or at least renders the integral connectors unreliable). 
         [0009]    What is needed then is a reusable bulk container with removable forkstraps, wherein the connectors affixing the forkstrap to the base are not integral to the base or the forkstrap and wherein the forkstrap can be separated from the base without using undo force while the connector, while in use, will provide sufficient retention force to prevent inadvertent separating during use. 
       SUMMARY OF THE INVENTION 
       [0010]    The present invention relates to a reusable shipping container having a forkstrap unit (or separate forkstraps) that is removably connected to the base of the container, and more particularly to such a container that uses a connector to connect the forkstrap unit to the base that is not integral to the forkstrap unit or the base. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    For a further understanding of the nature, objects, and advantages of the present invention, reference should. be had to the following detailed description, read in conjunction with the attached figures, wherein like reference numerals denote like elements. 
           [0012]      FIG. 1  is perspective of the base of a container showing a forkstrap unit affixed to the base using an embodiment of the forkstrap connector. 
           [0013]      FIG. 2  is a perspective view of Detail A with an embodiment of the forkstrap connector installed. 
           [0014]      FIG. 3  is an exploded perspective view of Detail A. 
           [0015]      FIG. 4  is bottom perspective view showing the embodiment of the forkstrap unit from  FIG. 1  installed on the embodiment of the base from  FIG. 1 . 
           [0016]      FIG. 5  is a perspective view of Detail B showing the embodiment of the forkstrap connector from  FIG. 3  fully installed. 
           [0017]      FIG. 6  is a perspective view of Detail B showing the embodiment of the forkstrap connector from  FIG. 3  with the locking pin removed. 
           [0018]      FIG. 7  is a perspective view of Detail B showing the embodiment of the forkstrap connector from  FIG. 3  disengaged. 
           [0019]      FIG. 8  is an explode perspective view of the embodiment from  FIG. 1 . 
           [0020]      FIG. 9  is an exploded perspective view of an embodiment of the forkstrap connector and locking pin. 
           [0021]      FIG. 10  is a partially exploded perspective view of an embodiment of the forkstrap connector and locking pin. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    The present invention is a shipping container for bulk goods. Referring to  FIG. 1 , container  1  comprises rectangular base  10 , forkstrap unit  50 , and connectors  100 . It should be noted that for many applications container I would include a plurality of sidewalls. These sidewalls could take on a multitude of configurations ranging from sidewalls that can be folded for shipment or rigid sidewalls. The particular configurations of walls is, however, not relevant to the present invention that relates to how the forkstraps are interconnected to the base. 
         [0023]    Base  10  further comprises a plurality of apertures  20 . In the illustrated embodiment, each aperture  20  is defined by a vertical surface that terminates in rim  22 ; the upper surface of rim  22  being below upper surface  12  of base  10  by a distance equal to the thickness of plate  110  of connector  100 . Rim  22  is surrounded by channel  24  for receiving skirt  112  of connector  100 . 
         [0024]    Connector  100  comprises plate  110 . Defined in the center of connector  100  is aperture  102  for receiving locking pin  140 . Plate  110  may be recessed as shown around aperture  102  in the illustration to allow head portion  142  of locking pin  140  to be flush with upper surface  12  of base  10  when locking pin  140  is fully inserted. Skirt  112  extends downward from the perimeter portion of plate  110 . 
         [0025]    Spaced apart from and inward of skirt  112 , barbs  120  extend downward from the lower surface of plate  110 . Each barb  120  terminates in outward-facing wedge-shaped portion  122 . The upper portion of wedge-shaped portion  122  forms ledge  124 . Each barb  120  may be joined to adjacent barbs  120  from the lower surface of plate  110  to an intermediate point to add rigidity as required for the particular application. Each barb  120  is additionally adapted to receive outward pressure from locking pin  140 . In the illustrated embodiment, this adaptation comprises rib  126  that extends inward from barb  120 . 
         [0026]    Locking pin  140  comprises head portion  142 . Extending downward from head portion  142  is shaft  144 ; shaft  144  having a diameter sufficient to apply an outward pressure on ribs  126 . Locking pin  140  further includes a retention mechanism to ensure that locking pin  140  remains in place once it is fully inserted. In the illustrated embodiment, this retention mechanism comprises a plurality of ramp-shaped retention protrusions  148  (best seen in  FIGS. 9 and 10 ) extending outward from shaft  144 . The upper surface of retention protrusions  148  are located such that when locking pin  140  is fully-inserted into forkstrap connector  100 , the upper surface of retention protrusions  148  impinge On the lower surface of plate  110 , preventing locking pin  140  from inadvertently being removed from forkstrap connector  100 . In an alternate embodiment, locking pin  140  can terminate in an annular ring (not shown), the annular ring having a diameter slightly greater than shaft  144 . Shaft  144  has a length sufficient to permit the upper surface of the annular to engage the lower surface of ribs  126  when locking pin  140  is fully inserted such that lower surface of head portion  142  is engaged with the upper surface of plate  110  (or the upper surface of the recessed area defined around aperture  102 ). 
         [0027]    Forkstrap unit  50  includes receptacles  52  arising from the upper surface of the forkstrap unit, with receptacles  52  being located to align with latching apertures  20  defined in base  10 . The upper portion of each receptacle  52  defines aperture  56 . The inner surface of receptacle  52  surrounding aperture  56  forms latching surface  58 . While the illustrated embodiment is drawn to an integrated forkstrap unit, the invention is equally applicable to containers using individual forkstraps. In such an application, each forkstrap would include a plurality of receptacles to align with a subset of apertures  20  in base unit  10 . 
         [0028]    When a connector  100  is inserted into an aperture  20  in base unit  10 , barbs  120  extend through aperture  56  in receptacle  52  with the wedge-shaped portions  122  of barbs  120  facilitating installation (at the upper end portion of wedge-shaped, portion  122  where the wedge is the widest, the barbs collectively are slightly further apart than the size of aperture  56  causing barbs  120  to be bent toward the center of aperture  56  as connector  100  is inserted). Once wedge-shaped portion  122  clears aperture  56  in receptacle  50 , barbs  120  spring back, causing ledge  124  to impinge on latching surface, thereby joining forkstrap unit  50  to base  10 . While the illustrated embodiment is drawn toward a configuration of four barbs, more or less barbs could be utilized (for example two opposing barbs) and the arrangement could be in a different pattern such as circular or triangular or some other shape (the shape of the apertures in the base and forkstrap unit would also be circular or triangular or other shape as the case may be). 
         [0029]    To augment the strength of the connection and to preclude forkstrap unit  50  from becoming inadvertently disconnected from base unit  10 , locking pin  140  is then inserted through aperture  106  in connector  100 . Once full inserted, connector  100  is fixed in place with retention protrusions  148  impinging against the lower surface of plate  110  and the lower surface of head portion  142  impinging against the upper surface of plate  110  (or the upper surface of the recessed area defined around aperture  102 ). Locking pin  140  thereby precludes barbs  120  from being bent inward and allowing forkstrap unit  50  to disconnect from base  10  inadvertently. 
         [0030]    If forkstrap unit  50  or connector  100  or both become damaged, replacement is facilitated by first removing locking pin  140 . Forkstrap unit  50  can then be separated from base  10  without the use of undue force. Thus, the central, and most costly, portion of container  1 , base  10  (and the sides), do not become scrap solely because forkstrap unit  50  or connector  100  is damaged. This is critical because forkstraps and connectors are the most commonly damaged portions of reusable shipping containers and the most common reason such containers have to be scrapped. 
         [0031]    The foregoing described embodiments are exemplary in nature and are not intended to limit the scope of the invention.