Abstract:
A pallet system for shipping a number of spools includes a pad which supports and retains a first layer of spools. A separator is disposed atop the first layer of spools and a second layer of spools is disposed atop the separator. Subsequent layers of spools and separators may be included in a stacked relationship, and a cap member is disposed atop the topmost layer of spools. The pad, cap, and separators form a stacked shipping unit and may include locking features and provisions for retaining straps.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims priority of U.S. Provisional Patent Application 61/473,374 filed Apr. 8, 2011, entitled “High Density Pallet System”, the contents of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]    This invention relates, generally, to packing systems. More specifically, the invention relates to pallet systems. In particular, the invention relates to pallet systems which allow for the high-density packing and shipping of cylindrical members such as spools of yarn, thread, or other filamentary material. 
       BACKGROUND OF THE INVENTION  
       [0003]    Filamentary material such as yarn, thread, and the like is frequently wound onto spools for shipping from a manufacturing facility to a use facility. These spools generally are configured to fit directly into end use manufacturing equipment. Typically, large numbers of wound spools are shipped to distribution or end use manufacturing facilities; hence, there is a need for a packing system which can securely retain such spools for shipping. In addition to being simple to use, such shipping systems should be light in weight, low in cost, and allow for the high-density packing of wound spools. 
         [0004]    Goods are increasingly being shipped via containerized freight systems which utilize standard-dimension freight containers. Hence, any cargo shipping system should be configured to be compatible with standard freight containers such that wasted space is minimized or eliminated, and maximum packing density achieved. Spools used for filamentary materials typically include a core portion about which the filamentary material is wound, and in many cases, portions of this core project from the spool so as to allow mounting of the core onto use or processing equipment. 
         [0005]    As will be explained in detail hereinbelow, the present invention comprises a palletized system which provides for the high-density packing of spool-wound material. The system of the present invention is configured to provide palletized stacks of spooled material which may be readily handled by forklifts, cranes, and other such processing equipment, and which are dimensioned so as to allow for high-density packing in standardized shipping containers. These and other advantages of the present invention will be apparent from the drawings, discussion, and description which follow. 
       BRIEF DESCRIPTION OF THE INVENTION  
       [0006]    Disclosed is a pallet system for retaining a plurality of spools of the type comprising a core having a filamentary material wound thereabout. The system includes a pad or pallet having a first face configured to rest on a support surface and a second face having a plurality of spool-engaging features defined thereupon. The spool-engaging features are each configured and operable to engage a spool so that the pad is capable of supporting a layer of spools on its second face in a predetermined pattern. The system further includes at least one separator having a first and second face, each face having a plurality of spool-engaging features defined thereupon in the predetermined pattern. The system further includes a cap having a first face with a plurality of spool-engaging features defined thereupon in the predetermined pattern. The components of the system are configured and operable so that in the use of the system, the second surface of the pad receives and supports a first layer of spools thereupon in the predetermined pattern, and the spool-retaining features of one of the separators engages the first layer of spools. Further in the use of the system, a second layer of spools is supported on the second face of the separator. In a typical application, a further number of separators and corresponding layers of spools are added to the pallet system, and the cap member is then disposed atop the topmost layer of spools so that its spool-engaging features engage those spools so as to form a completed shipping unit. 
         [0007]    In particular embodiments, the spool-engaging features may comprise conical protrusions which engage the core portions of the spool. In other instances, the spool-engaging features may comprise recesses which receive projecting portions of the cores of the spools. In further embodiments, the components of the pallet system may be configured to define one or more grooves which operate to receive a strapping member. The cap and/or pad members may be configured to define further features such as forklift access channels, stabilizing legs, forklift guides, lift pads for robotic devices, locking features, and the like. 
         [0008]    The components of the pallet system may be fabricated from a polymeric material such as high molecular weight polyethylene, high-density polyethylene, low-density polyethylene, acrylonitrile-butadiene, -styrene, polypropylene, polyethylene, and combinations thereof. In some instances the polymer may include a reinforcing material therein. The pallet components may be formed by thermoforming. In some instances, the components of the system may be configured so that the plurality of spools may be disposed in a staggered matrix. In some embodiments, the first face of the pad component is configured so as to be engageable with a second face of the cap so that completed shipping units may be readily stacked atop one another. 
         [0009]    Further disclosed is a method for packing a series of spools of material through the use of the pallet system of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0010]      FIG. 1A  is a perspective view of a spool of filamentary material; 
           [0011]      FIG. 1B  is a cross-sectional view of the spool of  FIG. 1A ; 
           [0012]      FIG. 2A  is a perspective view of one embodiment of pad member in accord with the present invention, showing the first face thereof; 
           [0013]      FIG. 2B  is a top plan view of the pad of  FIG. 2A  showing the second face thereof; 
           [0014]      FIG. 3A  is a perspective view of an embodiment of cap in accord with the present invention showing the second face thereof; 
           [0015]      FIG. 3B  is a top plan view of the cap of  FIG. 3A  showing the first face thereof; 
           [0016]      FIG. 4A  is a perspective view showing a first face of a separator in accord with the present invention; 
           [0017]      FIG. 4B  is a top plan view of the separator of  FIG. 4A  showing the second face thereof; 
           [0018]      FIG. 5A  is a perspective view of a palletized stack of spools utilizing a system of the present invention; 
           [0019]      FIG. 5B  is a cross-sectional view of the stack of  FIG. 5A ; 
           [0020]    FIGS.  5 C, 5 D and  5 E are enlarged views of portions of the cross-sectional view of  FIG. 5B ; 
           [0021]      FIG. 6A  is a plan view of a bottom surface of another embodiment of pad member of the present invention; 
           [0022]      FIG. 6B  is a cross-sectional view of a portion of the pad of  FIG. 7A  showing details of the spool-retaining feature; 
           [0023]      FIG. 7A  is a perspective view of another embodiment of cap member which may be utilized in the present invention, showing its first face; 
           [0024]      FIG. 7B  is a plan view of the cap member of  FIG. 8A  showing its second face; 
           [0025]      FIG. 8A  is a perspective view showing a first face of another embodiment of separator in accord with the present invention; 
           [0026]      FIG. 8B  is a plan view showing a second face of the separator of  FIG. 9A ; 
           [0027]      FIG. 9A  is a cross-sectional view of a palletized stack of spools in accord with the second embodiment of the invention; 
           [0028]      FIG. 9B  is an enlarged cross-sectional view of a portion of the stack of  FIG. 10A ; and 
           [0029]      FIG. 10  is a perspective view of two stacked pallet units as configured for shipping, in accord with the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0030]    The palletized system of the present invention includes components which allow for the high-density stacking of a plurality of layers of wound spools. As such, the system includes a pad member, a cap member, and a plurality of separator members configured to be disposed therebetween and retain a number of layers of wound spools. The system of the present invention may be configured in a variety of implementations, and some illustrative examples thereof are presented herein. 
         [0031]    Referring now to  FIGS. 1A and 1B , there is shown a typical wound spool of the type which may be shipped utilizing the system of the present invention.  FIG. 1A  shows a perspective view of the wound spool  10  showing the projecting core portion  12  and the filamentary material  14  wound thereabout.  FIG. 1B  is a top plan view of the spool  10 , and  FIG. 1B  is a cross-sectional view of the spool. It is to be understood that while these figures show a spool having a projecting core portion, the pallet systems of the present invention may also be used in conjunction with spools of a different configuration. 
         [0032]      FIGS. 2A and 2B  show various views of one particular embodiment of pad component (also referred to as a pallet member) of the system of the present invention.  FIG. 2A  shows the pad  16  in a perspective view, taken from its first (or lower) face, which will rest on a floor or other support surface in the use of the pad.  FIG. 2B  shows the pad in a top plan view as taken from its second (or upper) face, which in the use of the pad will support a plurality of spools thereupon. As will be seen from the figures, the pad includes a number of spool-engaging features defined on its second face. The spool-engaging features, for example feature  18 , engage and retain the spools in a predetermined pattern. In the  FIG. 2  embodiment, this pattern comprises a three by four matrix and as such will support twelve spools. Other patterns are also within the scope of the invention. The pad member  16  is further configured to include notches which can accommodate strapping or other tie downs which can facilitate binding components of the system into a tight stack, and in the illustrated embodiment, these notches are shown at reference numeral  20 . The pad is also configured to accommodate a lift fork when the system is assembled. In this regard, the illustrated embodiment, as best seen in  FIG. 2A , includes pallet foot features  21  on its first face which define openings  22  configured to allow access to a lift fork. 
         [0033]    Referring now to  FIGS. 3A and 3B , there is shown an embodiment of cap member (also referred to as a cover member) which may be used in the system of the present invention.  FIG. 3A  is a perspective view of the cap member  26  showing a second (top) face, and  FIG. 3B  is a top plan view showing the first (bottom) face of the cap. The cap member  26  has a number of spool-retaining features  18  defined upon the second face in a predetermined pattern which corresponds to the same predetermined pattern in the pad member. The cap  26  also includes notches  20  disposed and configured to retain a packing strap. 
         [0034]      FIGS. 4A and 4B  illustrate an embodiment of separator  28  which may be utilized in the present invention.  FIG. 4A  is a perspective view of the separator  28 , illustrating a first face thereof; and  FIG. 4B  is a top plan view of the separator showing a second face thereof. The separator  28  includes a pattern of spool-engaging features  30  on both its first and second faces. The spool-engaging features  30  are in a pattern which corresponds to the same pattern used in the cap and pad members. As shown in  FIG. 4 , the spool-engaging features of this particular embodiment include a through hole, for example through hole  32 . This through hole accommodates the projecting portions of the core of the spools as will be explained hereinbelow, and thus allows for higher density packing of spools in a stacked array. The separator  28  also includes notches  20  which accommodate packing straps as discussed above. 
         [0035]      FIG. 5A  shows a perspective view of a palletized stack of spools  10  utilizing the above-described system of the present invention. As will be seen, a pad  16  forms the base of the stack, a cap  26  forms the top of the stack, and separators  28  retain spools  10  therebetween.  FIG. 5B  shows the stack in a sectional view taken along line A-A in  FIG. 5A . As will be seen, the through hole openings in the separators allow for the very tight stacking of the spools. 
         [0036]    Referring now to  FIG. 5C , there is shown a partial, enlarged view of the stack shown in cross section in  FIG. 5B  taken at reference point  5 C.  FIG. 5C  illustrates the manner in which the top cap  26  engages the spool  10  and fits into the core portion thereof.  FIG. 5D  is a detail taken at point  5 D in the  FIG. 5B  drawing and shows the separator  28  and the manner in which it is configured to allow projecting portions  12  of the spool  10  to fit therethrough so as to provide for a high-density stack.  FIG. 5E  shows a view taken at point  5 E of the stack of  FIG. 5B  and shows the bottom pad  16  in engagement with the spool  10 . As will also be seen, the configuration of the bottom pad  16  accommodates the projecting portion of the core  12 . 
         [0037]    In view of the foregoing, it will be appreciated that the system of the present invention allows for the secure, high density, reliable stacking of spooled material. Various stacking configurations may be achieved through the use of various combinations of the aforedescribed pads, caps, and separators of the present invention so as to provide maximum filling of shipping containers of differing sizes. As will be seen, the pads and caps may be further configured so that their outer faces can positively engage one another so as to allow several stacked units each comprised of a pad, a cap, separators, and spools disposed therebetween, to be placed atop one another. By appropriately selecting the number of layers and units, a stacked assembly may be prepared so as to fit standard cargo containers. As will be understood in the art, these stacks may be banded together by strapping material utilizing the notches as previously discussed. 
         [0038]    As mentioned above, the system of the present invention may be configured in a variety of embodiments, and another such embodiment is illustrated in  FIGS. 6-10  which follow. The system of these figures is configured to retain a plurality of spools in a staggered relationship in a four by four matrix, although other staggered configurations are readily implemented utilizing the components of this embodiment. 
         [0039]      FIG. 6A  is a plan view showing a first face of a particular pad  16  of the system of the present invention, and features thereof which correspond to the pad member previously described will be referred to by like reference numerals. As in the previous embodiment, the pad includes a number of spool-engaging features defined on its upper (second) face, and one such spool-engaging feature is shown at reference numeral  18  in  FIG. 6B  is a cross-sectional view of one of the spool-engaging features  18  as taken along line  6 B- 6 B of  FIG. 6A . 
         [0040]    The pad member  16  is further configured to include features including lid locks  50 , pallet feet  52 , and strapping detents as shown for example at reference numeral  54 . The pallet may also include fork leveling pads, as shown at reference numeral  58 , and these pads can aid in guiding a forklift and in that regard work together with associated fork openings  22  as defined by the pallet feet  52 . The pallet may further include robotic vacuum lift pads as shown for example at reference numeral  56 , and these pads provide a smooth surface which is engageable by a robotic lifting device. 
         [0041]      FIGS. 7A and 7B  show a lid or cap member  26  which may be utilized in conjunction with the pad or pallet member of  FIGS. 6A and 6B . The cap member is shown in perspective view in  FIG. 7A  which illustrates the cap&#39;s first, spool-engaging, face. The cap member  26  has a number of spool-retaining features  18  defined thereupon in a predetermined pattern which corresponds to the same predetermined pattern in the pad member.  FIG. 8B  is a plan view of the cap  26  showing the second face thereof. The cap further includes robotic lift pads  58  as previously described, as well as pallet-engaging foot landing pads  60  which aid in stabilizing stacks of palletized goods. Lid locks  62  may be included, and strapping detents  54  as previously described may likewise be included. 
         [0042]      FIG. 8A  is a perspective view, showing a first (front) face of a separator  28  comprising a four by four staggered matrix, which may be employed in combination with the aforedescribed pad and cap members.  FIG. 8B  is a plan view showing a second (back) face of the separator  28 . The separator  28  includes a pattern of spool-engaging features  30  on both its first and second faces disposed in a pattern which corresponds to the pattern of the cap and pad members. The separator  28  of  FIGS. 8A and 8B  differs from the aforedescribed separator shown in  FIGS. 4A ,  4 B and  5 D insofar as it includes a number of large conical members  64  which engage the spools to be loaded thereupon so as to facilitate loading of the assembly. The separator includes robotic vacuum lift pads  58  as previously described and can include notches or other features which are configured to accommodate packing straps. 
         [0043]    Referring now to  FIG. 9A , there is shown a cross-sectional view of an assembled, palletized stack of spools utilizing the pad, separators, and cap of the foregoing  FIGS. 6-8 . As will be seen, the stack is comprised of a cap  26 , a pad or pallet  16 , and seven stacked four by four arrays of spools  10  wherein each of the layers of spools is separated from the others by a separator  28 . 
         [0044]      FIG. 9B  is an enlarged view of a portion of the cross-sectional view of  FIG. 9A , showing portions of two stacked spools  10  with a portion of a separator  28  therebetween, and specifically illustrating the manner in which the cone feature  64  projects into a portion of the spool  10 .  FIG. 9B  also shows a portion of a conical feature  66  of a cap member projecting into the spool. As will be appreciated, the configuration of this embodiment of the present invention provides for a densely packed, mechanically stable stack of spools. 
         [0045]      FIG. 10  shows a perspective view of a fourteen-layer stack of spools employing the system of the present invention. As will be seen, the staggered relationship of the spools will allow stacks to be interfit when disposed in a shipping container so as to maximize the amount of space which is filled. The fourteen-layer stack of  FIG. 10  is comprised of two units, each of which includes a pad  16  and a cap  26  member. A first seven-layer stack  70  has a second seven-layer stack  71  placed there atop, and in this regard, the pad member  16  of the second stack  71  is configured to engage the cap member  26  of the first stack  70 . 
         [0046]    In general, the pad, cap, and separator members are fabricated from polymeric materials, since such materials are generally low in cost, high in strength, lightweight, and dimensionally stable. Some specific polymeric materials utilized to fabricate these members include high molecular weight polyethylene, high-density polyethylene, low-density polyethylene, acrylonitrile-butadiene-styrene (ABS), polypropylene, other polyethylenes, and various combinations of the foregoing materials. As is known in the art, the polymers may include reinforcing materials such as fibrous materials therein as well as fillers, coloring agents, and the like. In specific instances, the components are fabricated from thermoplastic polymers utilizing various molding or shaping processes. In one specific instance, the components are fabricated by thermoforming polymeric stock. In other instances, they may be fabricated by injection molding or other such processes. In yet other instances, the components may be manufactured from thermosetting polymeric materials or curable resin materials. All of such implementations are within the scope of the present invention. 
         [0047]    The foregoing describes some specific implementations of the present invention. Other implementations, modifications, and variations thereof will be apparent to those of skill in the art. The foregoing drawings, discussion, description, and examples are illustrative of specific embodiments of the present invention but are not meant to be limitations upon the practice thereof. It is the following claims, including all equivalents, which define the scope of the invention.