Abstract:
Embodiments of the invention may encompass a container storage system having a modular storage rack including framing elements each having a locking component of at least one end thereof and a counterpart locking component on another end; each locking element being engagable with each other; and wherein the storage rack is assembled to maximize storage capacity within the shipping container. It may also include a modular array having at least one elongated framing element with at least one key on at least one end thereof having an elongated rotatable member having at least one flange extending radially therefrom; at least one other elongated framing element having at least one opening being shaped to receive the key; wherein the framing elements are arranged to form the array and the key and the opening are used to engage the framing elements by inserting the key into the opening and rotating the key.

Description:
[0001]     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/794,183, filed Apr. 21, 2006. 
     
    
     BACKGROUND  
       [0002]     The invention relates to the field of racks for shipping and storing industrial products. More particularly, the invention relates to modular shipping and storage racks and components therefor.  
         [0003]     As is well known to those working in the shipping and storage industries, there is a veritable plethora of rack systems used for the transport and/or storage of countless numbers of items ranging from fasteners, to automobiles, to heavy industrial equipment and so forth. Generally, such rack systems are designed for a particular purpose, such as the transport or storage of a particular type of item, be it tools, gears, bumpers, wheels, etc. As a rule, a rack system designed for a particular purpose is not readily adaptable for another purpose. For example, rack systems optimized for storage make poor shipping containers, as they are generally built to take primarily downward loads. In addition, such systems ordinarily provide little protection to the merchandise from the jolts and jarring that are inherent to stevedoring operations. On the other hand, rack systems optimized for shipment of merchandise generally make poor storage devices. To the applicant&#39;s knowledge, the design of rack systems which accommodate a wide range of products of varying size in both shipping and storage functions is still in its infancy.  
         [0004]     What is needed is a modular rack system, the configuration of which can be readily modified to accept a variety of merchandise, and which can be ganged, expanded, contracted, or fitted with accessories, as needed. Additional desirable qualities would be that the modular rack system, when assembled and loaded, be easily moved by forklift and readily fitted with lift cables, and that when no longer needed for storage or transport purposes, it be easily disassemblable, stowable, and transportable.  
         [0005]     Further, a significant problem in shipping is the need, in a more security conscious world, of inspecting or testing articles in shipping containers entering or leaving a county&#39;s ports. Generally, articles are packed densely into shipping containers to maximize the return on the expense of renting the container. These articles are typically stacked box on box, without any rack or internal storage container. Consequently, it is very time consuming and expense to inspect or test articles in these containers, due to the need to remove the articles box by box for inspection. A further advantage of the invention would be its adaptation for use within existing shipping containers, allowing ease of access to merchandise for inspection or testing, without the need to unpack the container.  
       SUMMARY OF THE INVENTION  
       [0006]     Embodiments of the invention may encompass a shipping container storage system having a modular storage rack that includes a plurality of framing elements, each of the framing elements having a locking component of at least one end thereof and a counterpart locking component on another end thereof, each of the locking component and the counterpart locking element being engagable with each other to connect said framing elements together; and wherein the modular storage rack is assembled in a configuration to maximize storage capacity within the shipping container.  
         [0007]     A further embodiment of the invention may include a modular array having at least one elongated framing element; at least one key on at least one ends of the framing element, the key having an elongated rotatable member and at least one flange extending radially from the elongated rotatable member; at least one other elongated framing element; at least one opening on the other elongated framing element, the opening being shaped to receive the key; wherein the framing elements are arranged to form the array and the key and the opening are used to engage the framing elements by inserting the key into the opening and rotating the key. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     For a better understanding of the invention, together with other objects, features and advantages, reference should be made to the following detailed description which should be read in conjunction with the following figures wherein like numerals represent like parts.  
         [0009]      FIG. 1  is an isometric view of a modular rack system constructed from a plurality of coupler blocks, beams, and shock-absorbing feet, in accordance with the invention;  
         [0010]      FIG. 2  is an isometric view of a complex modular rack array constructed from multiples of the basic components depicted in  FIG. 1 ;  
         [0011]      FIG. 3  is an isometric view of a coupler block, a plurality of which are used to construct the modular rack system;  
         [0012]      FIG. 4  is a top plan view of a coupler block;  
         [0013]      FIG. 5  is a cross-sectional view of a coupler block taken along line  5 - 5  of  FIG. 4 ;  
         [0014]      FIG. 6  is an isometric view of a beam;  
         [0015]      FIG. 7  is an end view of a beam perpendicular to its longitudinal axis;  
         [0016]      FIG. 8  is an isometric view of a shock-absorbing foot;  
         [0017]      FIG. 9  is a side elevational phantom view of a shock-absorbing foot;  
         [0018]      FIG. 10  is an isometric view of drawer guides which can be mounted within the modular rack system;  
         [0019]      FIG. 11  is a close-up view of the guide-to-rack attachment area identified in  FIG. 10 ;  
         [0020]      FIG. 12  is a side elevational view of a modular rack system following the installation of drawer guides and a drawer;  
         [0021]      FIG. 13  is a side elevational view of a modular rack system having laterally-mounted shock-absorbing feet;  
         [0022]      FIG. 14  is an isometric view of two modular rack systems, one of which has been stacked on top of the other;  
         [0023]      FIG. 15  is a diagram of a container rack system in accordance with aspects of the invention.  
         [0024]      FIG. 16  is a diagram of a further embodiment of a connector system in accordance with aspects of the invention.  
         [0025]      FIG. 17  is a diagram of another further embodiment of a connector system in accordance with aspects of the invention. 
     
    
     DETAILED DESCRIPTION  
       [0026]     For simplicity and ease of explanation, the invention will be described herein in connection with various exemplary embodiments thereof. Those skilled in the art will recognize, however, that the features and advantages of the invention may be implemented in a variety of configurations. It is to be understood, therefore, that the embodiments described herein are presented by way of illustration, not of limitation.  
         [0027]     At the outset, and as shown in the drawing and in particular  FIG. 1 , it is to be noted that the new modular rack system, as depicted in an example of a rack array generally denoted  10 , may incorporate multiple units of two principal components: a coupler block  11 , and a beam generally denoted  12 . It will be noted that the beams are labeled  12 A through  12 D, as they may be of different lengths or fitted with additional accessories. For example, although beams  12 A and  12 D may be of identical length, beams  12 D may incorporate bracket,s which will be hereinafter described. Each coupler block  11  may be designed such that it has six cubically-arranged faces; 3, each face being equipped with an appropriately-sized aperture  14  for slidably receiving one end of a beam  12 . The received end of beam  12  may be locked within the aperture by means of a retaining pin  15 , which may be inserted within a pin insertion hole  16  in the coupler block, thereby also passing through a locking hole (not shown in this Figure) in the end of the received beam. Each of the six apertures  14  may have associated therewith a pin insertion hole  16  in the coupler block for receiving a retaining pin  15 . The modular rack system also may incorporate multiple shock absorbing feet  17 , each of which may be nestingly secured to a coupler block  11  positioned at each lowermost corner of the rack array  10 . It will be noted that each of beams  12 D may incorporate a pair of forklift stirrups  18 , which provide not only correct positioning of lifting forks, but also prevent the array  10  from tipping during lifting. Such forklift stirrups  18  may be mounted with fasteners, slidably mounted within the T-shaped longitudinal grooves of the beam  12  (see the detailed description of  FIG. 6 ), or may be welded to the beams  12 .  
         [0028]     It should be evident that a variety of rack array configurations may be formed by combining coupler blocks  11  and beams of various lengths  12  in a virtually limitless number of ways.  FIG. 2 , which depicts one such combination, includes forty-one coupler blocks  11 , seventy-five beams  12 , and six shock-absorbing feet  17 . Although the rack array of  FIG. 2  is only one possible combination of coupler blocks  11  and beams  12 , it demonstrates the versatility of the new modular rack system.  
         [0029]     Referring now to  FIG. 3 , certain features of the coupler block  11  that were described while referring to  FIG. 1  are now more clearly visible. For example, three apertures  14 A,  14 B, and  14 C of the six apertures (generally denoted  14 ) in coupler block  11  are visible, as are a pair of retaining pins  15 A and  15 B, which are shown inserted in their respective pin insertion holes  16  in the coupler block  11 . The right-most pin  15 B is also visible within aperture  14 A. It will be noted that each retaining pin (generally denoted  15 ) may have a pull ring  31  attached thereto. The interior of each aperture  14  may incorporate four alignment guide rails  32  (one on each aperture wall  33 ), two of which are visible in aperture  14 A, and one of which is visible in aperture  14 C. The coupler blocks  11  may be cast as a single unit from a lightweight structural metal such as aluminum or magnesium, or it may be formed as a composite item, having a central connector assembly (not shown in its entirety in this Figure) formed, ideally, from a high-strength wear-resistant metal, that is insert molded within a durable body  34  which incorporates the apertures  14  and guide rails  32  and gives the coupler block  11  its general exterior shape.  
         [0030]     The central connector assembly, which may be fabricated as a welded-up unit from a metal such as steel or titanium, may extend into each of the six apertures of the coupler block  11 . If a coupler block is fabricated in such a manner, the square tube  35  visible in aperture  14 A may be such an extension. If a coupler block  11  is cast or machined as a single unit, then the body  34  and the entire central connector assembly, which includes square tube  35 , may simply be part of a single casting. In any case, each square tube extension  35  may have an anchoring hole  36  therethrough for receiving a retaining pin  15 . This anchoring hole  36  may be aligned with the pin insertion hole  16  through the coupler block body  34 .  
         [0031]     The beams  12  of a rack system array may be tied to this central connector assembly. If the coupler block  11  is formed as a composite item, the coupler block body  34  may be formed from any suitable, durable material, such as a plastic, a lightweight metal such as aluminum or magnesium or alloys thereof, or the like. Useful plastic materials include ABS resins, epoxy resins, high-density polyethylene, polyalkylenes, polycarbonates, and polyurethanes used either alone or in combination with reinforcing high-tensile-strength fibers, such glass or graphite. When made of a moldable material, the coupler block body  34  may be formed by any suitable molding process known to the skilled artisan. It is to be understood that it is not the particular material or the method by which it is molded that is a critical factor, but rather that the body be formed from a suitable durable material. The coupler block body  34  may theoretically have any desired three-dimensional polygonal configuration (e.g., pyramidal, pentahedral, cubic, octahedral or decahedral). A cubic configuration permits rectangular rack arrays. As will be noted each of the six faces  13  of the coupler block body  34  may have a boss  37  which surrounds the aperture  14 . The boss  37  imparts additional strength to the coupler block body  34  without a corresponding increase in total weight.  
         [0032]     Referring now to  FIG. 4 , certain features of the coupler block are more clearly defined. For example, in this view, all four guide rails  32  within an aperture  14  are seen, as is a retaining pin insertion hole  16  (the longitudinal axis of which is perpendicular to the page), boss  37 , and the square-cross-section tube  35 . Also visible is a central threaded hole  41 . The aperture  14  of each face may have a threaded hole  41 .  
         [0033]     Referring now to  FIG. 5 , this cross-sectional view is shown mainly to expose the central connector assembly  51  of a composite coupler block  11 . This central connector assembly may be formed as a single piece of metal by casting or machining, or it may be welded-up from various components. Visible in this view are four square tube extensions  35 A,  35 B,  35 C and  35 D, which are associated with four of the six faces of the coupler block. In this view, tube extensions  35 A,  35 B,  35 C and  35 D have been sliced open. One of each pair of anchoring holes  36  in tube extensions  35 A and  35 B is visible in one wall of square tube extensions  35 A and  35 B, where as half of each anchoring hole  36  in the opposing walls of square tube extensions  35 C and  35 D are visible. It should be emphasized that the interior structure visible in a cross-section through any of the six faces will be essentially the same.  
         [0034]     The welded-up central connector assembly  51  may be formed from hollow interior cube  52 . One square tube extension  35  may be welded to each of the six faces of this interior cube  52 . In the center of each region of a face of the interior cube  52  may be a threaded hole  41 . The threaded holes  41  in opposing sides not only permit passage of a supporting cable through the center of the coupler block  11 , but also provide a threaded anchor for a bolt which may be used to attach a shock-absorbing foot  18  to any of the six faces  13  of the coupler block  11 . Each edge of the interior cube  52  may have a fin  54  welded thereto. The eight fins  54  (one for each edge of the cube) may be imbedded within the material from which the coupler block body  34  is cast, and assist in maintaining the welded-up central connector assembly  51  firmly anchored within the coupler block body  34 .  
         [0035]     Referring now to  FIG. 6 , certain features of the beam  12  which were previously alluded to are now clearly visible. For one embodiment of the invention, each beam  12  may be extruded from a light, high-strength metal such as aluminum, magnesium or an alloy thereof. Each beam  12  may be of more or less square cross-section, having chamfered edges  61  and a hollow core  62  which extends the entire length of the beam. As heretofore stated, each end of the beam  12  may incorporate a locking hole  63 , both of which are now visible in this view. Each of the four sides of the beam may incorporate a T-shaped longitudinal groove  64 , which, like the hollow core  62 , may extend the entire length of the beam. Threaded fasteners  65 , which are essentially bolts having a square or rectangular head sized to fit the groove  64 , may be inserted within the groove and employed to removably mount protective covers, flooring, shelves, doors, hinges, and so forth on the beams  12 . With the flooring and shelving so installed, merchandise may then be loaded on the modular rack array  10 . Furthermore, by the disposition of suitable auxiliary components, it is possible to install drawers within a rack array. Such an installation is shown in  FIGS. 10 and 11 .  
         [0036]     Referring now to  FIG. 7 , the substantially square cross section of a beam  12  is clearly evident. Each of the four T-shaped grooves  64  is clearly visible, as is the hollow central core  62 .  
         [0037]     Referring now to  FIGS. 8 , a shock-absorbing foot  18 , which is generally of cubical shape, also has a recess  81 T on the top thereof, which nestingly receives the face and boss of a coupler block.  
         [0038]     Referring now to  FIG. 9 , an embodiment of the shock-absorbing foot  18  may be formed from a body  90  formed from flexible polymeric material, such as butyl or natural rubber (or a combination of the two) that may be reinforced in the sidewalls  91 S and in the floor portion  91 F, much like a vehicle tire, with high-tensile cord  92 , such as nylon, kevlar, polyester, rayon, etc. The top recess  81 T and a bottom recess  81 B may be formed in the body. Each recess  81 T or  81 B may be sized to nestingly receive the face  13  and boss  37  of a coupler block  11 . A generally inflexible insert  93  may be embedded within the flexible polymeric material of a roof portion  91 R, central core portion  91 C, and the bottom portion  91 B of the foot  18 . A compressible internal chamber  94  may be formed by the sidewalls  91 S, the roof portion  91 R, and the floor portions  91 F of the foot  18 .  
         [0039]     A valve  95  may be incorporated in the foot  18 , which allows the chamber  94  to be pressurized with air or some other appropriate gas to accommodate loads of varying weights. A hollow-core mounting bolt  96  may be used to secure the foot  18  to a coupler block  11 . The internal chamber  94 , particularly when inflated, defines a compressible shock absorber or bumper which not only protects an attached coupler block  11 , but also protects the entire rack array  10  and the merchandise stored therein from excessive jarring and shock. In order to determine the shock loading to which the rack array  10  has been subjected during transit, loading and unloading, an electronic shock recorder may be installed on the rack assembly in any suitable position. It is to be appreciated that in assembling a rack, such as that disclosed in  FIG. 1 , that further stacking can be achieved and that a foot  18  can be disposed between adjacent vertical or horizontal associated coupler blocks  11  for heavier loads and for lateral impact. Also, a plurality of lugs can be nested together at any desired intersection. Interconnecting struts and lugs can also be used.  
         [0040]     Referring now to both  FIGS. 4, 6  and  9 , as there is no blockage between threaded holes  41  of opposed faces, a cable may be threaded through a coupler block  11  via any opposed pair of threaded holes  41 . As has been seen, each beam  12  has a hollow center, which permits a cable or lifting rod to be strung up through the hollowcore mounting bolt inserted within a shock-absorbing foot  18 , through a coupler block  11 , through the core of a beam  12 , then through another coupler block, and so forth, until reaching the top of the rack array, where it may be utilized, in combination with other cables so positioned, to lift the rack array. A swedged-on cable end may be used to anchor the cable and also hold the foot  18  on the rack array.  
         [0041]     It is to be appreciated that electronic tagging devices may be associated with the modular rack system for identification, inventory control and shipment routing. For example, one or more electronic modules may be attached to the rack system. A radio-frequency identification tag having rewritable on-board memory may be used for shipment identification, inventory control and shipment routing functions. A simpler electronic module might only provide a rewritable memory for storing an electronic inventory list and shipping manifest.  
         [0042]     Referring now to  FIG. 10 , the modular rack array of  FIG. 1  is shown with a pair of drawer guides  1001  installed between vertically-oriented beams  12 D. As is seen in the close-up view of  FIG. 11 , the end of each drawer guide may have a pair of tabs  1101 , each tab having a bolt hole by means of which the tab may be secured to a threaded fastener  65  inserted within the T-shaped groove  64  of the beams  12 D. In the front elevational view of  FIG. 12 , a drawer  1201  having a handle  1202  is shown mounted on the drawer guides  1001 . An electronic module  1203 , which may provide at least some of the features described in the foregoing paragraph, is shown secured within an unused aperture  14  of a coupler block  11 .  
         [0043]     Referring now to  FIG. 13 , a pair of shock-absorbing feet  17  may be laterally mounted on the upper-most coupler blocks  11 . The use of the shock-absorbing feet  17  in this manner protects the rack array and any merchandise stored therein from lateral shocks.  
         [0044]     Referring now to  FIG. 14 , two rack arrays  10 A and  10 B are shown with rack array  10 B being stacked on top of rack array  10 A. In this case, the upper-most coupler blocks of the lower rack array  10 A may be nested in the shock-absorbing feet mounted on the lower-most coupler blocks of the upper rack array  10 B. The nesting feature maintains stacking alignment during transport of the rack arrays, even in the face of normal vertical and lateral forces that occur during shipment.  
         [0045]     It should now be fully appreciated that the design of the coupler block  11  and longitudinal beams  12  enables the erection of a virtually limitless variety of rack arrays using multiple coupler blocks  11  and a plurality of beams  12  of desired lengths. In addition, the new modular rack system is ideally suited to computer-controlled “pick and place” robotic assembly. The modular rack system herein described also accommodates electronic monitoring of shock forces to which the system is subjected.  
         [0046]     Further embodiments of the invention are illustrated in  FIGS. 15 and 16 . As previously noted, the inspection of goods coming into ports in containers is problematic in that it is time consuming (and unrealistic) to unpack entire containers to conduct random inspections. Embodiments of the invention provide a real solution to this significant security problem. The invention has the ability to provide access to the gross container, without the need to unpack the container. Embodiments of the invention may include sub-set racks that can be rolled in and out of the shipping containers.  
         [0047]     As is clear from the above descriptions, the sub-set rack would not add substantial weight to the gross container wait. For example, the rack could be steel frame with aluminum side walls. Moreover, most container loads are filled to capacity based upon volume long before the maximum weight limit of the container is reached, allowing significant margin for any additional weight from the rack system of the invention.  
         [0048]     An illustration of an embodiment of the invention along these lines is shown in  FIG. 15 . As shown in  FIG. 15 , the sub-set container rack may be configured as a segmented system that is shaped to fit within the space of the shipping container. One embodiment, for example, may include two separate racks, each of which has a top and a bottom segment. Thus, in a conventional twenty foot container, two racks measuring 8 ft.×8 ft.×10 ft. may be used, having a top and a bottom section. Alternatively, in a forty foot container, four such racks may be used as an example. Moveable/removeable shelves and side panels may be further included, providing easy access to various sections of the container cargo. Sub-containers, such as those having pull out drawers might also be used, again enabling local access to pieces of cargo without the need to unpack significant portions of the container.  
         [0049]     In such an embodiment, or others, a further type of connector mechanism may be used. An example of this is illustrated in  FIGS. 16 and 17 . As shown in these figures, the connector mechanism may comprise a key based system, wherein an elongated rotatable element (substantially cylindrical, for example) having one or more flanges extending radially therefrom may be inserted into a portion of one frame element for joining two framing elements together. Each frame element may also have an end having a key and another end having an opening shaped appropriately to receive the key, making the framing elements somewhat interchangeable. The end of a frame element containing a key may be joined to the end of another framing element having a key opening. The key may be placed into the opening and then turned, thereby inhibiting the two sections from being separated as the flange sections of the key contact the surface of the framing element. The opening may also have inclined radial sidewalls, creating a compression type fitting.  
         [0050]     The key may include a hole in the substantially cylindrical element, allowing a rod or other elongated abject to be inserted into the hole for rotating the key. In one embodiment, the framing element may have an opening across a face thereof to allow such bar to be inserted to the key.  
         [0051]     The key may be mounted to the framing element, for example, using a mounting screw as illustrated. Of course, those of ordinary skill in the art that the key may be mounted using any number of conventional means and configurations. Also, those of ordinary skill in the art will appreciate that framing elements may also be connected at a corner or angle by including a key extending at an angle from the end or side of the framing element, and similarly an angled opening on another framing element.  
         [0052]     Wheels or rollers may be included, along with a tow plate, allowing the racks to be wheeled in and out of the container. Lifting rails for forklifts, pallet jacks, etc. may also be included to the remove the racks in that manner.  
         [0053]     An omni type coupler may also be incorporated, allowing elements to be coupled both horizontally and vertically in one or more directions.  
         [0054]     In the above manner, embodiment of the invention may be used to solve the port embarkation inspection problem. The invention also allows faster packing of containers, as racks may even be preloaded at the factory or other source.  
         [0055]     The embodiments that have been described herein, however, are but some of the several which utilize this invention and are set forth here by way of illustration but not of limitation. It is obvious that many other embodiments, which will be readily apparent to those skilled in the art, may be made without departing materially from the spirit and scope of the invention as defined in the appended claims. Changes and modifications to the system may be made without departing from the scope and spirit of the invention as hereinafter claimed. For example, other means for securing the beams to the coupler blocks may be employed. Similarly, other types of coupler blocks and beams which similarly cooperate may also be used.