Abstract:
A reusable container and a method of using same to transport fragile, yet heavy loads, is provided. The reusable container, preferably made primarily from wood, includes a base member, at least one vertical member having one or more vertical support members capable of being received in one or more interlock pockets in the base member, a top or lid and a cargo support member. These components interact in such a way as to provide for ease of assembly and disassembly by a single person, and to provide a container having great strength when assembled. More specifically, the at least one vertical member interlocks with the base member and adjacent vertical members, thus minimizing the need for supplemental fasteners.

Description:
RELATED APPLICATIONS 
     This application is claiming the benefit, under 35 U.S.C. 119(e), of the provisional application filed Dec. 28, 2009 under 35 U.S.C. 111(b), which was granted Ser. No. 61/290,260. This provisional application is hereby incorporated by reference. 
    
    
     BACKGROUND 
     The invention relates to a reusable container capable of transporting fragile, yet heavy loads. More specifically, the invention relates to a rugged container which can be re-used multiple times and is readily assembled and disassembled for use and for return transport. A method of using such a container is also provided. 
     Those engaged in transporting fragile but heavy cargoes will appreciate the dilemma of creating a container which is able to withstand the considerable stresses applied to a container during multiple uses for transporting, for example, glass sheets, while at the same time being light enough to be easily handled, and readily disassembled, preferably by one person, and importantly, being cost effective, compared to other types of packaging/containers. The present invention satisfies these often conflicting objectives. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a reusable container which is capable of transporting fragile, yet heavy loads, for example a plurality of glass sheets or panels. 
     The container includes a base member, at least one vertical member having one or more vertical support members and being disposed in a receiving pocket in the base member, a top or lid disposed on or in the upper end of the at least one vertical member, and a cargo support member. 
     The aforesaid members interact in such a way as to aid ease of assembly of the container and to provide great strength to the container when assembled. More specifically, the at least one vertical member interlocks with one or more of the base member and adjacent vertical members, if any. Through such interlocking, the need for additional fasteners to assemble the container is minimized. 
     A method of using the container of the invention is also be provided. Although other materials may also be suitable, the container of the invention is preferably made from wood. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Additional objects, advantages and features of the present invention will become apparent from the following description and appended claims taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a perspective view of the fully assembled container according to an embodiment of the invention. 
         FIG. 2  is a perspective view of the base member according to the invention. 
         FIG. 3  is a perspective view of an end vertical member showing certain interlocking details according to the invention. 
         FIG. 4  is a perspective view of the front vertical member according to the invention. 
         FIG. 5  is a perspective view of the rear vertical member according to the invention. 
         FIG. 5 a    is a plan view of the rear vertical member of  FIG. 5  according to the invention. 
         FIG. 6  is a detail of  FIG. 1  showing the interlocking means between a side vertical member and the base member according to the invention. 
         FIG. 7  is a detail of  FIG. 1  showing the interlocking means of the rear vertical member and a side vertical member with the base member according to the invention. 
         FIG. 8  is a detail of  FIG. 1  showing the interlocking means of the front vertical member and a side vertical member with the base member according to the invention. 
         FIG. 9  is a perspective view of the top or lid member according to the invention. 
         FIG. 10  is a front and side view of the cargo support member according to the invention. 
         FIG. 10 a    is a perspective view of the cargo support member according to the invention according to the invention. 
         FIG. 11  is a perspective view of a locking strap that is suitable for use with the invention. 
         FIG. 12 a    is a perspective view of an alternative cargo support member according to the invention. 
         FIG. 12 b - d    show a variety of views of the components of the alternative cargo support member. 
         FIG. 13  is a perspective view of an alternative base member according to the invention. 
         FIG. 14  is a perspective view of the container according to the invention utilizing the alternative base member and alternative cargo support member in one of its possible positions. 
         FIG. 15  is a perspective view of the container according to the invention utilizing the alternative base member and alternative cargo support member in a second of its possible positions. 
         FIG. 16  shows a perspective view of a rear vertical member according to the invention including optional banding material locating notches. 
         FIG. 17  is a detail of  FIG. 1  showing an alternative means to that illustrated in  FIG. 6  for interlocking a side vertical member and the base member. 
         FIG. 18  shows the interlocking means of  FIG. 17  in interlocking engagement with the base member. 
         FIG. 19  shows a feature for preventing the undesirable displacement of a side vertical member during loading in one configuration of the container according to the invention. 
         FIG. 20  shows a view similar to  FIG. 19  with the front vertical member in place after, for example, loading of the container has been completed, in one configuration of the container according to the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention relates to a reusable container capable of transporting fragile materials, such as automobile windshields formed of glass, that are fragile but also quite heavy, requiring a very protective and robust container. A desirable container for this purpose should also be stable during loading, be easy to assemble, be collapsible for return shipping and maintain its integrity over many uses. The container of the present invention meets these, as well as other objectives. 
     The container of the invention utilizes a number of simple, but effective means to interlock various component members of the container, thus creating a stable, high strength structure even before the container is completely assembled. The positive interlock features also facilitates assembly, as it is clear to the assembler when the component members are properly in place. 
     While described in greater detail below, for example with regard to  FIGS. 7 and 8 , the interlocking features of interest include vertical side member supports  38  having a locking notch  40 . When vertical side member support  38  is placed in vertical member support interlock pocket  22 , locking notch  40  allows the vertical side member support  38  to engage side locking rail  18 . Inserting, for example, vertical front support member  34 , and/or vertical rear support member  36  into vertical support interlock pocket  22  already occupied, in part, by vertical side member support  38 , substantially locks all three of these component members  28 ,  30  and  26  together and to base member  12 . Rear cargo support locking rail  32  also allows locking of cargo support member  44  into place. 
     An alternative way to interlock, for example, a vertical side member support into the base member is illustrated in  FIGS. 17 and 18 . Rather than the locking notch  40  formed in vertical side support member  38 , a vertical support member  138  has been formed at a distal end thereof, namely, a locking foot  140 , thus forming a substantially “L” shaped portion which can be engaged with a horizontal member of base member  12 , for example, horizontal retaining member  139 . Interlocking engagement of locking foot  140  with horizontal retaining member  139  is shown in  FIG. 18 . As with the previously described interlocking of locking notch  40  with side locking rail  18 , this alternative interlocking structure, locking foot  140  and horizontal retaining member  139 , provides a very strong container requiring a minimum of additional fasteners. 
     Referring now to  FIG. 2 , base member  12  can be any shape, but is preferably rectangular in configuration, and is preferably made up of front base rail  14 , parallel rear base rail  16  and one or more parallel interior base rail(s)  23 . Substantially perpendicular to the aforesaid base rails  14 ,  16 ,  23  and mechanically fastened thereto are, preferably, one or more base member support(s)  13 , side locking rails  18  and one or more horizontal load support(s)  20 . The length of side locking rails  18  and horizontal load support(s)  20 , which are substantially the same, define the distance between front base rail  14  and rear base rail  16 . Conversely, the distance between side locking rails  18  substantially defines the length of front base rail  14 , rear base rail  16 , and interior base rail(s)  23 . 
     Preferably, in each of the four corners of the base member  12 , a vertical member support interlock pocket  22  is formed by the intersection of front base rail  14  and a first interior base rail  23  or rear base rail  16  and a second interior base rail  23 , and, perpendicular thereto, first and second side locking rails  18  and first and second horizontal load supports  20 . 
     As will be further discussed, the vertical member support interlock pockets  22  are capable of receiving and holding one or more vertical member supports and to provide a positive interlock function for front, rear and side vertical members  28 ,  30 , and  26  respectively, of the inventive container. 
     Referring to  FIG. 3 , the container includes at least one, but preferably two, vertical side members  26 . The side member  26  is made up of one or more vertical side member supports  38 , preferably including at a predetermined location thereon, a locking notch  40 , which when the vertical side member support  38  is fully engaged in vertical member support interlock pocket  22 , will lockingly engage with side locking rail  18 . The vertical side member supports  38  are separated by a distance substantially equal to the length of locking side rail  18 . One or more horizontal side member brace(s)  27  have a length substantially equal to that of the locking side rail  18 . Optionally, one or more side member angle braces  19  extend at a predetermined angle between horizontal side member braces  27 . All braces  27 ,  29  are mechanically fastened to vertical side member supports  38 . 
     Referring to  FIG. 4 , the illustrated container  10  includes at least one vertical front member  28 , which is made up of one or more of vertical front member support(s)  34 . Mechanically fastened to vertical front member support(s)  34  and substantially perpendicular thereto, are preferably, one or more horizontal front brace members  35 . 
     Referring to  FIG. 5 , the container includes at least one vertical rear member  30 , which is made up of one or more vertical rear member support(s)  36 . Mechanically fastened to vertical rear member support(s)  36 , and substantially perpendicular thereto, are preferably one or more horizontal rear brace members  31 . Also, mechanically fastened to vertical rear member support(s)  36 , but best seen in  FIG. 5 a   , is substantially horizontal cargo support locking rail  32 . 
       FIG. 9  is a perspective view of top or lid member  24  which is made up of at least one top rail  25  and substantially perpendicular and mechanically fastened to the at least one top rail  25 , at least one top brace  25   a.    
     Referring now to  FIG. 1 , an assembled container  10  is shown, utilizing the component members previously described herein, as well as an exemplary locking strap  42 , shown in more detail in  FIG. 11 . Not shown in  FIG. 1  is cargo support member  44 , but cargo support member  44  is best seen in  FIG. 10 , and as placed in container  10 , in  FIG. 10   a.    
     While the type of mechanical fasteners utilized to join various component parts of the present convention is not critical, exemplary mechanical fasteners include nails, screws and staples. 
     Cargo support member  44  may be formed from any suitable material, but is preferably a corrugated material, more preferably corrugated cardboard. 
     Locking strap  42  may also be made of any suitable material, but is preferably made of a polymeric material having a unidirectional locking feature, for example a plastic “zip-tie”. 
     Horizontal load supports  20  may, optionally, be provided with a material having resilient and/or non-slip properties on the upper surface of same where it supports a peripheral edge of a glass sheet, thus providing some “give” and avoiding cargo shifting, accordingly reducing glass breakage. 
     While other methods of assembling the container  10  are possible, a preferred method of assembly involves at least the following steps:
         providing a rectangular base member  12  having in each corner thereof, a vertical member support interlock pocket  22  formed by the intersection of: front base rail  14  or rear base rail  16 , parallel first and second interior base rails  23  and substantially perpendicular thereto, side locking rails  18  and horizontal load supports  20 ;   inserting one or more vertical side member supports  38  of vertical side member  26  into both a front and a rear vertical member support interlock pocket  22 ;   engaging locking notches  40  on front and rear vertical side member supports  38  with side locking rail  18 ;   inserting vertical rear member supports  36  of vertical rear member  30  into two rear vertical member support interlock pockets  22 , locking the vertical rear member  30  and the one or more vertical side members  26  into base member  12 ;   placing cargo support member  44  into the container  10 , and engaging the locking portion  50  of cargo support member  44  with cargo support locking rail  32 , a component of vertical rear member  30 ;   loading the cargo into container  10  so as to be supported by cargo support member  44  and one or more of horizontal load supports  20 ;   inserting vertical front member supports  34  of vertical front member  28  into two front vertical member support interlock pockets  22 , locking the vertical front member  30  and the one or more vertical side members  26  into base member  12 ;   placing top  24  onto container  10 , into closing contact with horizontal brace members  27 ,  31  and  35 , so as to protectively enclose the cargo;   supplementally interlocking the various vertical members  26 ,  28 ,  30  of the container, and with base member  12  by use of a plurality of locking straps  42 ; and   optionally wrapping metal or plastic banding at selected locations around container  10 .       

     The capabilities of the container of the invention may be expanded by utilizing a multi-position cargo support member  144  in place of the cargo support member  44  previously described herein. Cargo support member  144 , illustrated, for example, in  FIG. 12 a   - d,  is preferably made of wood. Components of cargo support member  144  preferably include: at least one vertical cargo support member  146  having at least one interlock notch  154  formed at a predetermined location in vertical support member  146 ; a first horizontal cargo support member  148  and a second horizontal cargo support member  150 , each horizontal cargo support member  148 ,  150  having one or more interlock notches  156  formed at a predetermined location in each of the horizontal support members  148 ,  150 . As can be seen in  FIG. 12 a   , the interlock notches of the at least one vertical cargo support member and first and second horizontal cargo support members  148 ,  150  can be joined to form interlocking cargo support joint  152 , forming a self-supporting, reusable cargo support member without the need for any additional mechanical fasteners. Vertical cargo support members  146  also supportingly interact with horizontal load supports  120  in base member  112 , as will be further described hereinafter. 
     Base member  112  is substantially similar to base member  12 , and includes, for example, front base rail  114  rear base rail  116 , interior base rails  123 , horizontal load supports  120 , side locking rails  118 , vertical support member interlock pockets  122  and base member supports  113 . Additionally, however, mechanically fastened to a horizontal load support  120  is at least one substantially “L”-shaped horizontal cargo support member locating block  124 . 
     As shown in  FIG. 14 , multi-position cargo support member  144  is placed inside a partially assembled container according to the invention, in a first position, such that second horizontal cargo support member  150  is in locating contact within the “L”-shaped horizontal cargo support member locating block  124 . Additionally, vertical cargo support members  146  supportingly contact horizontal load support members  120 . In this configuration, cargo support member  144  holds the cargo in a relatively upright position, on the order of 5-10° from vertical. 
     As shown in  FIG. 15 , multi-position cargo support member  144  is again placed inside a partially assembled container according to the invention, in a second position, such that first horizontal cargo support member  148  is in locating contact with only one leg of the “L” of horizontal cargo support member locating block  124 . Vertical cargo support members  146  again supportingly contact horizontal load support members  120 . In this configuration, cargo support member  144  holds the cargo in a somewhat more inclined position, on the order of 10-15° from vertical. 
     In connection with the utilization of cargo support member  144 , it may be desirable to supplementally secure the cargo in the container by means of metal or plastic strapping or banding material. To ensure optimal location of such banding material in relation to cargo support member  144 , one or more band locating notches  202  may be formed in rear vertical member  130 , as shown in  FIG. 16 . 
     An optional feature referred to herein as a “stop block”, is intended to prevent undesired lateral displacement of vertical side member support  38  in the interlock pocket  22  proximate the front side of the container, prior to insertion of vertical front member support  334  into interlock pocket  22  due to, for example, ongoing operations of loading cargo into the container.  FIG. 19  shows the disposition of stop block  332  in interlock pocket  22 , proximate the base of vertical side member support  38 , which has been inserted into interlock pocket  22 . It should be appreciated that in order to insert vertical side member support into the interlock pocket  22 , while at the same time avoiding stop block  332  and engaging locking notch  40  with side locating rail  18 , it may be necessary to initially insert vertical side support member into interlock pocket at an angle less than 90°, and then to raise the vertical side member support to the vertical in a second insertion step. Once inserted by whatever method, it can be readily appreciated that lateral displacement of the vertical side support member  38  in the interlock pocket  22  is substantially prevented. The stop block may be made from any suitable material, but is preferably made from wood, and is securely attached to base member  12 , preferably to base member support  13  or front base rail  14  by any suitable fasteners.  FIG. 20  shows vertical front support member  334 , which has been modified, i.e., made shorter compared to standard front vertical support member  34 , in order that vertical front support member  334  is adapted to rest firmly on an upper surface of stop block  332 , while also still being positively retained in interlock pocket  22 . Thus, as previously described herein, various members interact with each other to create a robustly interlocked structure and, thus, a strong container in this optional configuration as well as in the previously described configurations. 
     In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiments. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.