Abstract:
A method of securing large rolls of compressible materials on flat transport cars, including (a) placing a first set of longitudinally spaced U-shaped brackets on the transport car, each of the U-shaped brackets consisting of a horizontal cross member between a pair of vertical legs of a height no greater than the roll diameter, (b) loading a plurality of the large rolls on the cross member to define a first row of the rolls, (c) strapping the first row of rolls together, (d) repeating steps (a) and (b) with additional sets of brackets to stack a selected number of additional rows of rolls above the first row, wherein the brackets of each set are aligned with the brackets associated with the rows therebeneath with the legs connected to so as to carry a significant portion of the weight of the rolls, and (e) strapping selected adjacent rows of rolls together.

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
     Not applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
     Not applicable. 
     REFERENCE TO A MICROFICHE APPENDIX 
     Not applicable. 
     TECHNICAL FIELD 
     The present invention is directed toward transporting materials, and particularly toward transporting large rolls of compressible materials. 
     BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIOR ART 
     Long distance transportation of large objects is not unusual, given that the large objects are typically manufactured at limited locations though their use is desired in many locations. Such transportation is often conveniently accomplished by train and/or truck. For example, large pipes may be conveniently stacked on train cars and/or truck trailer beds. However, the amount of such objects which may be stacked on a single car and/or bed is limited by a number of factors, including load stability, weight and strength. For example, while pipes may be stacked on top of one another, they cannot be stacked so high as to crush the pipes on the bottom of the stack, nor may they be stacked in a manner which risks that they will dangerously break off of the stack or shift so as to cause the car or trailer to be dangerously imbalance and perhaps tip over during transport. 
     The above problems may be exacerbated when the object being transported is compressible. In such instances, it may be impossible to stack such objects on top of one another to any significant degree without risking that the bottom objects of the stack be damaged. One example of such compressible materials is large scale plastic polyethylene liners such as may be used for ground cover in a wide variety of applications such as land fills. Such liners are often provided in rolls which may range in length from 14 feet to 35 feet, and with a diameter of 18 inches to 46 inches. Heretofore, such rolls have often been transported in open top train cars, where the walls of the cars restrain the rolls. However, such a manner of transport has either been susceptible to damaging the rolls on the bottom of the load, and/or has required that limited numbers of rolls may be included on each car to prevent and/or minimize such damage. Further, such transport is limited by the availability of specialized open top cars, and the amount of rolls which can be carried on a single car are limited by the height of the car walls. Moreover, accessing the load for loading and unloading may be hindered by the presence of the car walls, with workers potentially hindered from reaching certain areas when necessary to connect and/or disconnect lifting structures. 
     The present invention is directed toward overcoming one or more of the problems set forth above. 
     SUMMARY OF THE INVENTION 
     In one aspect of the present invention, a method of securing large rolls of compressible materials on flat transport cars is provided, including the steps of (a) placing a first set of longitudinally spaced U-shaped brackets on the transport car, each of the U-shaped brackets consisting of a horizontal cross member between a pair of vertical legs of a height no greater than the roll diameter, (b) loading a plurality of the large rolls on the cross member to define a first row of the rolls, (c) strapping the first row of rolls together, (d) repeating steps (a) and (b) with additional sets of brackets to stack a selected number of additional rows of rolls above the first row, wherein the brackets of each set are aligned with the brackets associated with the rows therebeneath with the legs connected to so as to carry a significant portion of the weight of the rolls, and (e) strapping selected adjacent rows of rolls together. 
     In one form of this aspect of the present invention, the brackets are aligned by telescopically connecting the legs in substantially vertical alignment. In a further form, the legs have axial openings, and the aligning is accomplished by inserting rigid members into the opening with the rigid members extending between adjacent legs. 
     In another form of this aspect of the present invention, one or more middle roll of each of the rows is chocked. 
     In still another form of this aspect of the present invention, the bracket legs are stacked to selectively support the cross members apart a distance less than the selected diameter. 
     In yet another form of this aspect of the present invention, the rows on the bracket cross members each have R rolls thereon and, after step (e), a first additional row having R-1 rolls is nested thereon, the first additional row is strapped to the row on which it is nested, and all of the rows are strapped together. 
     According to yet another form of this aspect of the invention, a method of transporting large rolls of compressible materials from a shipping location to a distribution center is provided, including the steps of securing the rolls on a flat transport car according this aspect of the invention, moving the flat transport car to the distribution center, and, at the distribution center, removing the rolls row by row from the flat transport car by releasing the straps around the top-most row and removing the rolls of the top-most row wherein. For each row on one of the bracket sets, removing further consists of (I) ensuring that at least one middle roll is chocked to prevent rolling of at least one middle one of the rolls, (ii) removing the rolls other than the at least one middle one of the rolls from the car, (iii) removing the at least one middle one of the rolls from the car last, and (iv) removing the U-shaped bracket which supported the removed rolls; and repeating steps (I)–(iv) for all rows destined for distribution from the distribution center. 
     In another aspect of the present invention, a support structure for transporting large rolls of compressible material on flat transport cars is provided, including a vertical base legs securable to a car, a plurality of U-shaped brackets having a horizontal cross member between two vertical legs of a height less than the roll diameter, and securing members adapted to secure the brackets with the legs stacked vertically with the cross members spaced vertically a distance less than the selected diameter. The cross member is adapted to support a row of a plurality of the rolls of compressible material, and the bracket cross members are adapted to secure rolls of the compressible material thereon with the secured legs supporting a substantial portion of the weight of the rolls located above the bottom row. 
     In one form of this aspect of the present invention, the securing members comprise longitudinal joining members sized to fit within a central openings of the legs. In a further form, the securing members are selectively securable to the legs. In a still further form, means are provided for releasably securing the joining member in selected legs of the brackets, whereby the joining members each extend into the central opening of adjacent bracket legs stacked vertically on top of one another. 
     In another form of this aspect of the present invention, sets of straps are adapted to extend about one or more rows, wherein every row secured by one set of straps is also secured to at least one other row by a second set of straps. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an illustration of a railroad car on which are stacked large rolls of compressible materials according to the present invention; 
         FIG. 2  is an exploded view of the  FIG. 1  structure highlighting the arrangement of the top three rows; 
         FIG. 3  is an exploded view of the  FIG. 1  structure with the top three rows removed and highlighting the arrangement of the fourth row; 
         FIG. 4  is an exploded view of the  FIG. 1  structure with the top four rows removed and highlighting the arrangement of the third row; 
         FIG. 5  is an exploded view of the  FIG. 1  structure with the top five rows removed and highlighting the arrangement of the second row; 
         FIG. 6  is an exploded view of the  FIG. 1  structure with the top six rows removed and highlighting the arrangement of the first row; 
         FIG. 7  is a side view of a bracket as used in the illustrated embodiment of  FIGS. 1–6 ; and 
         FIG. 8  is a perspective view of a portion of a bracket leg with a connecting pipe. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates a flatbed railroad car  10  on which a plurality of large rolls  20  of compressible materials are stacked thereon according to the present invention for transport. While a railroad car  10  is illustrated, it should be understood that the present invention could also be advantageously used for transport of rolls  20  on other large vehicles, such as truck trailers. 
     In the illustrated embodiment, there are four rows  21 ,  22 ,  23 ,  24  of five rolls  20  each topped by three nesting rows  25 ,  26 ,  27  of five, four and three rolls  20  respectively. 
     The rows  21 – 27  of the rolls  20  are advantageously variously banded together for stability, for example, by four inch nylon straps. For example, in the illustrated structure with seven rows  21 – 27 :
     a. A set of suitable bands or straps  30  is provided around each of the bottom four rows  21 – 24  at spaced locations along the length of the rolls  20 .   b. Additional sets of bands or straps  32  are also provided around the bottom two rows  21 – 22  and the next two rows  23 – 24 .   c. A set of bands  34  is provided around the bottom four rows  21 – 24 .   d. The top three rows  25 – 27  are secured together by a set of bands or straps  36 .   e. Additional set of bands  38  extends around the top three rows  25 – 27  and the two rows  23 – 24  therebeneath.   f. Finally a set of straps or bands  40  also extends around all of the rows  21 – 27 .   

     It should be appreciated that the exact number and arrangement of bands will be dependent upon the particular rolls  20  and arrangement of rolls  20  used in a given instance, and that the present invention is not limited to the above described and illustrated arrangement of rolls  20 , rows  21 – 27  and band sets  30 – 40 . For example, the present invention may be advantageously usable in instances where larger or smaller rolls are used, and/or in which more or less than five rolls as illustrated are included in each roll, and/or more or less rows of rolls are stacked. Further, it should be appreciated that the number of bands in each set of bands may vary depending upon the size and weight of the rolls  20 , as well as the strength of the bands  30 – 40 , and that the invention is not limited to the specific arrangement of bands  30 – 40  illustrated in the detailed example of the Figures. However, it should be appreciated that the band sets  30 – 40  should most advantageously overlap, whereby individual groups of rolls  20  secured by one band set are additionally secured to other groups of rolls  20  by other band sets, and that each set of bands  30 – 40  will include at least two bands, generally near the opposite ends of the rolls  20 . However, the bands should not be placed too near the ends of the rolls  20  to prevent them from possibly snagging on the ends due to movement which occurs during transport. 
     Each full width row  21 – 25  of rolls  20  is also advantageously supported by a support frame  50  defined by U-shaped brackets  52 . As best illustrated in  FIG. 7 , the brackets  52  include a cross member  54  with parallel legs  56  on opposite ends. 
     Advantageously, the bracket legs  56  may have a height which is approximately the diameter of the rolls  20  expected to be transported. In this manner, allowing for some compression of the material of the rolls  20  resting on the cross member  54  (as illustrated by the rolls  20  shown in phantom in  FIG. 7 ), each roll  20  of rows  21 – 24  may support substantially only its own weight as it rests on the cross member  54 , without weighing down significantly on the roll  20  therebeneath, and without being significantly weighed down by rolls  20  above it. 
     The support frame  50  consists of brackets  52  suitably stacked with the legs  56  aligned so as to support the weight of the rows  21 – 27  through the leg height. Specifically, suitable aligning configurations may be used, such as a hollow leg  56  within which a suitably strong support  58  (e.g., a steel pipe  58 ) may be telescopically received. The pipe  58  is supported to extend from the upper end of the leg  56 , for example, by a bolt  60  through the leg  56 , whereby the hollow bottom of the leg  56  of a bracket  52  stacked thereon is held in stacked alignment. Further, the stacking support between the legs  56  may be provided, for example, by direct abutment of the legs  56 , or may be provided by securing the pipe  58  to both legs  56 , or by the pipe  58  abutting the bolts  60  of stacked legs  56  on opposite ends of the pipe  58 , with the pipes  58  in those cases providing the vertical support between the legs  56 . Moreover, it should be appreciated that the brackets  52  may be advantageously stacked without being secured together whereby the brackets  52  may be removed by simply lifting them from above without requiring disconnecting of any latch or lock or the like. 
     The lowermost bracket  52  may be suitably secured to the bed of the train car  10 . Alternatively, it should be appreciated that the bed of the car  10  may serve to support the bottom row  21 , and individual legs may be suitably mounted to project from the car bed, without connection by any cross member. Suitable pallets or load spreading mats  70  may also be provided at the bottom, as well as pallets or other suitable separators or spacers  72  (e.g., 2″×4″ timber or ¾″ sheets of 4′×8′ plywood) (see, e.g.,  FIG. 2 ) between the rows  21 – 25  if desired, to facilitate later unloading of the rolls  20 , including placement and removal of the straps or bands. Pallets  70  at the bottom of the load may provide spacing to allow for later addition of bands or straps should they be deemed necessary (e.g., if other bands  30 – 40  happen to break during transport before reaching the desired destination). 
     It should be appreciated that still other removably stackable bracket leg structures may be used within the broad aspect of the present invention, with the brackets suitably configured to support the weight of a row of rolls  20  disposed on the cross member  54 , with a substantial portion of the weight of the rolls  20  supported through the stacked legs  56 . To accommodate different size rolls, for example, the pipe  58  may be selectively securable to different positions on the legs  58 , whereby different selected spacings between the cross members  54  may be provided. Alternatively, different length pipes could be used depending on the required spacing between rolls. Also, the legs  56  could be adjustable in length to accommodate different rolls  20  (with different diameters), for example, with spacers provided for placement over the pipes  58  when larger diameter rolls  20  are used, whereby the weight is transmitted through the stack of aligned spacers and legs  56 . It should also be appreciated that the U-shaped brackets  52  could be downwardly open within the scope of the present invention. The important requirement is that the brackets serve to support significant amounts of the weight of the rows through the compression of the aligned legs  56 . 
     It should further be appreciated that the width of the brackets  52  (i.e., the length of the cross members  54 ) may advantageously be substantially a multiple of the diameter of the rolls  20  expected to be transported. In that manner, the rolls  20  may be located between the legs  56  with minimal lateral spacing, whereby minimal undesirable side to side load shifting will be possible. However, such a size is not required within the broad scope of the present invention, and the width of the cross members  54  may instead, for example, be selected to maximize the width within the restrictions of the transport vehicle such as the railroad car  10 . Moreover, suitable chocks  74  (see, e.g.,  FIG. 2 ) may be advantageously used to restrict side to side shifting of the rolls  20 . Such chocks  74 , when used, may be advantageously secured, for example, to the spacers  72 , to prevent displacement in transit. It has been found that the chocks  74  perform most advantageously if not positioned too tightly against the rolls  20  in order to minimize any tearing which might result, for example, from impacts during transport. Guide rails may also be advantageously provided along the inside of the floor chocks in order to eliminate the snagging of bands and the material on the rolls  20 . 
     Reference will now be had to  FIGS. 2–6  which illustrate the process or method according to which rolls  20  transported as illustrated in  FIG. 1  may be safely and advantageously unloaded from the railroad car  10  at its intended destination. 
     First, the bands  36 ,  38 , 40  extending around the upper three rows  25 – 27  are suitably removed (e.g., by cutting). At that point, the rolls  20  of the top (seventh) row  27  may be suitably lifted from the stack (e.g., by a lifting crane such as is known in the art), preferably one at a time. After the top row is removed, the rolls  20  of the next (sixth) row  26  are similarly removed. Since these rolls  20  nest between the rolls of the rows therebeneath, there is no great risk of the rolls rolling laterally during as each is removed. 
     At this point, the bottom five rows  21 – 25  remain, each row consisting of five rolls  20  supported between bracket legs  56 . 
     Removal of the remaining top row (the fifth row)  25  is accomplished as follows. First, it should be ensured that the center roll  20   c  is chocked. If the row  25  is was not chocked prior to transport, suitable chocks  74  should be provided to ensure that the center roll  20   c  will not roll laterally. With the center roll  20   c  so secured, two rolls  20   a,    20   b  on one side may be suitably lifted, and then the two rolls  20   d,    20   e  on the other side may similarly be lifted. At that point, the center roll  20   c  may be safely lifted. It should be appreciated that unloading in this manner will safely ensure that the load is not overloaded on one side or the other, as might otherwise occur as a result of load shifting during transport, and thereby any danger of tipping over of the load may be avoided. 
     Once the fifth row  25  is removed, the brackets  52   a  supporting that row may be lifted off of the brackets  52   b  therebeneath as shown in  FIG. 2 . At least straps  36  may also be easily pulled clear, as well as the chocks  74 , thereby exposing the fourth row  24  as the top row. 
     The fourth row  24  may then be suitably removed in a manner similar to that described for the fifth row  25 , with any remaining bands extending around it suitably removed (e.g., bands  30 ,  32  and  34 ), and the center roll  20   c  suitably chocked and then two rolls  20   a,    20   b  removed from one side, then two rolls  20   d,    20   e  removed from the other side, then finally the center roll  20   c.  At that point, the brackets  52   b,  spacers  72  (if any), and the chocks  74  are removed to expose the third row  23  as the top row as illustrated in  FIG. 3 . 
     Removal of the third row  23 , then the second row  22 , then the bottom row  21  may follow in a similar manner as illustrated in  FIGS. 4–6 . However, it should be appreciated that the necessity to remove the center roll  20   c  last is reduced for the lower rolls given that the risk of tipping of the load is reduced for lower rows given the lower height. 
     It should be appreciated that loading of a railroad car  10  in accordance with the present invention may proceed in essentially inverse order to the above described unloading process. 
     Specifically, the first row  21  may first be loaded onto the bottom brackets  52   e  resting on the car  10 , together with any desired pallets  70 , spacers  72  and chocks  74  (as shown in  FIG. 6 ). Further, all bands  30 ,  32 ,  34 ,  40  which wrap beneath the bottom row  21  may also be laid on the car  10  beneath the row  21  (though only band set  30  is illustrated in  FIG. 6 ). 
     Once all the rolls of the first row  21  are in place and the bands secured therearound are secured (i.e., band set  30 ), the next set of brackets  52   d  is suitably stacked on the bottom brackets  52   e,  along with any other desired pallets  70 , spacers  72 , chocks  74  and any new bands  30  extending beneath the second row  22 . The rolls  20  of the second row  22  are then added on the cross members  54  of the second set of brackets  52   d,  and all bands secured over the top of that row  22  are secured (i.e., bands  30  and  32 ). 
     This process is repeated for the third, fourth and fifth rows  23 – 25 , with bands laid beneath and secured over the rows as appropriate (i.e., band sets  30 ,  32  and  38  lay beneath the third row  23  and band set  30  is secured over the third row  23 ; band set  30  lays beneath the fourth row  24  and band sets  30 ,  32  and  34  are secured over the fourth row  24 ; and band set  36  lays beneath the fifth row  25 ). 
     Thereafter, the rolls  20  of the sixth row  26  are nested on top of the rolls  20  of the fifth row  25 , and then the rolls  20  of the seventh row  27  are nested on top of the rolls  20  of the sixth row  26 . 
     Finally, the band sets  36 ,  38 ,  40  extending over the top (seventh) row  27  are secured therearound. It should be appreciated that the above loading and unloading process enable the safe, reliable and efficient transport of large rolls of compressible materials. 
     It should now be appreciated that the present invention provides a loading and unloading method by which large rolls of compressible materials may be easily, reliably, safely and efficiently transported over long distances, wherein the integrity of the rolls may be protected during such transport. 
     Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained.