Patent Publication Number: US-2005127072-A1

Title: Collapsible shipping container

Description:
REFERENCE TO CO-PENDING APPLICATION  
      This patent application claims priority to co-pending United States provisional application for patent filed on Oct. 23, 2003, having Ser. No. 60/513,731, and entitled “Collapsible Shipping Container,” which is incorporated by reference into this disclosure. 
    
    
     BACKGROUND OF THE INVENTION  
      The present disclosure relates to shipping containers. More particularly, the present disclosure relates to collapsible and stackable shipping containers that can be easily reduced in size for return shipping.  
      Shipping containers are used to transport plants or other items around the country or continent. For instance, plants may be grown or cultivated all year round in a warmer region of the country, such as in a USDA Plant Hardiness Zone Region 10, and then transported from the place of origin to a zone 4 region destination during warmer months for resale by nurseries in that region. The shipping containers typically have a base that is adapted to interface with a forklift, and upstanding walls attached to the base and supporting a set of shelves. The plants are loaded onto the shelves, sometimes in flats, for transport.  
      Once the plants are transported to the destination, the grower is faced with the dilemma of what to do with the shipping containers. Often, simply returning the empty containers to the place of origin is not a cost effective option. Shipping costs are typically charged for each square foot of shipping space used, and sending a load of empty containers back to the place of origin can double the total shipping costs for the grower. In practice, the costs of shipping empty containers back to the place of origin prevent growers from realizing suitable profit margins. Instead, many growers have opted for disposable, or single use, shipping containers to transport plants. Disposable shipping containers appear to be the preferred product of choice to reduce shipping costs in transporting plants.  
      Disposable shipping containers, however, are not without disadvantages. Disposable shipping containers must have sturdy construction to prevent or minimize damage to the plants, and preferred disposable containers are not inexpensive. In addition, disposable containers are wasteful. Accordingly, there is a continuing need to create a sturdy, and cost effective shipping container that can be inexpensively transported when empty.  
     SUMMARY OF THE INVENTION  
      The present disclosure is directed to collapsible shipping containers that include a sturdy construction to minimize damage to contents during shipping. The collapsible shipping containers can be reused and shipped empty back to the place of origin yet are more cost effective than a disposable shipping container. The collapsible shipping containers can be disassembled and reassembled. In one working example, parts of four disassembled shipping containers can be disposed within and stacked into one assembled shipping container in a system. Thus, a system of five shipping containers can be shipped back to the place of origin in the same amount of space as a single shipping container.  
      The shipping containers and system of shipping containers of the present disclosure include several advantages. Each shipping container is sturdy and can protect the contents to be shipped from damage. In one example, shipping containers can withstand over forty round trips before losing effectiveness. The cost of the shipping containers in one example is less than five times as expensive a disposable shipping container. Accordingly, the grower is able to realize substantial savings in shipping costs in using the shipping containers and systems of the present disclosure over standard shipping containers or the conventional disposable shipping containers.  
      In one aspect, the present disclosure is directed to a collapsible shipping container. The collapsible shipping container includes a base having a generally planar base surface and a plurality of receiving terminals. The receiving terminals are connected to a pair of generally parallel cross members connected to the base surface. Upstanding walls having upright supports are removably attached to the base at the receiving terminals. The upright supports extend generally perpendicular to the base surface. Each of the upstanding walls includes a plurality of spaced-apart shelving support members extending between the upright supports. The upstanding walls are adapted to be removably connected to at least one shelf. The collapsible shipping container is adapted to be disassembled and reassembled at the base, upstanding walls and the at least one shelf.  
      In another aspect, the present disclosure is disclosure is directed to a system of stacked collapsible shipping containers. The system includes an assembled shipping container having a base with a generally planar base surface and a plurality of receiving terminals. The receiving terminals are connected to a pair of generally parallel cross members connected to the base surface. Assembled upstanding walls having upright supports removably attached to the base at the receiving terminals. The upright supports extend generally perpendicular to the base surface. Each of the upstanding walls includes a plurality of spaced-apart shelving support members extending between the upright supports. The upstanding walls are adapted to be removably connected to at least one shelf. The system also includes at least one disassembled shipping container having a plurality of disassembled upstanding walls disposed between the assembled upstanding walls of the assembled shipping container. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is an exploded partial view of a shelving assembly in accordance with one embodiment of the present disclosure.  
       FIG. 2  is a cross-section of a cross member shown in  FIG. 1 .  
       FIG. 3  illustrates a side view of one of the cross members from  FIG. 1  in greater detail, with part shown in phantom.  
       FIG. 4  shows the embodiment of  FIG. 1  with the pallet assembled to the two cross members.  
       FIG. 5  is an exploded view of shelf uprights positioned relative to the cross members.  
       FIG. 6  is an exploded view showing how shelves are inserted.  
       FIG. 7  is a side view of a portion of the shelving system with shelves mounted thereon.  
       FIG. 8  illustrates one embodiment of how the shelf uprights are assembled for return shipping.  
       FIG. 9  is an exploded view of a shelving assembly in accordance with another embodiment of the present disclosure.  
       FIG. 10  is a partial view of a system of nested and interlocked shelving assemblies of  FIG. 9 .  
       FIG. 11  is a cross-section of a portion of the shelving assembly of  FIG. 9 .  
       FIG. 12  illustrates a system of shelving assemblies of  FIG. 9  prepared for return shipping. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      This disclosure relates to collapsible and stackable shipping containers. The disclosure, including the figures, describes the shipping containers with reference to a several illustrative examples. For instance, the disclosure proceeds with respect to a pair of example shipping containers described below. However, it should be noted that the present invention could be implemented in other forms, as well. Also, the present disclosure is with respect to the shipping containers for plants for illustrative purposes only. Other examples, and other contents, are contemplated and are mentioned below or are otherwise imaginable to someone skilled in the art. The scope of the invention is not limited to the few examples, i.e., the described embodiments of the invention. Rather, the scope of the invention is defined by reference to the appended claims. Changes can be made to the examples, including alternative designs not disclosed, and still be within the scope of the claims.  
       FIG. 1  shows an exploded partial view of a shelving assembly constructed in accordance with the present disclosure. The shelving assembly includes a base, such as a conventional pallet  10 , which includes laterally oriented supports  12  and decking slats  14 . Pallet  10  is formed in a conventional manner. First and second cross members  16  and  18  can be removably attached to the ends of the pallet  10 . Cross members  16  and  18  are illustratively formed of an elongated angle iron shaped portion with a pair of upright receiving terminals  20  and  22  disposed on opposite ends thereof. The size of cross members  16  and  18  is just larger than the external periphery of one of the ends of pallet  10 . Therefore, cross members  16  and  18  can be assembled over the top of opposite lateral ends of pallet  10 , as illustrated by arrows  24 , as shown in  FIG. 4 .  
       FIGS. 2 and 3  show more detailed views of the cross member  16 .  FIG. 2  is a cross-sectional view of cross member  16  taken along the section line  2 - 2  shown in  FIG. 1 .  FIG. 2  better illustrates that cross member  16  is formed of an angle iron portion  30  and that the upright receiving terminal  20  extends above an upper portion of angle iron  30 . Of course, the term angle iron used herein is simply to describe the shape of the spanning portion of cross member  16 , and is not to be interpreted as a limitation to the material of cross member  16 . Indeed, cross member  16  can be formed of iron, aluminum, titanium, plastic or polymer material, or any other desired material.  FIG. 3  is a side view of cross member  16  taken in the direction indicated by arrow  40  shown in  FIG. 1 .  FIG. 3  illustrates upright receiving terminal  22  and further shows that the angle iron portion  30  of cross member  16  is sized just large enough to receive the end of lateral support  12  and the end decking slat  14  of pallet  10 .  
       FIG. 5  shows a further portion of the shelving assembly in accordance with one embodiment of the present invention.  FIG. 5  shows an exploded view of cross members  16  and  18 , along with a pair of uprights  44  and  46 , and further including a pair of braces  48  and  50 . In the illustrative embodiment, uprights  44  and  46  each include upright supports  52  and  54  that are connected to one another by slide rails  56 . The lower portion of upright supports  50  and  52  are sized to be received within an interior of terminals  20  and  22 . Of course, terminals  20  and  22  could be sized to be received within the lower portion of upright supports  52  and  54 . The upper ends of upright supports  52  and  54  are sized to receive the lower ends of braces  48  and  50  therein. In the illustrated embodiment, uprights  48  and  50  include pivotal supports  60  and  62  that are pivotally connected to uprights members  48  and  50  at pivot points  64  and  66 . The distal ends of supports  60  and  62  include apertures  68  and  70  therein. When assembled, the apertures  68  and  70  are aligned with corresponding apertures  72  and  74  on upright supports  52  and  54 . Once the apertures are aligned, securing pins  76  and  78  are lockably inserted through the aligned apertures to hold members  48  and  50  in place within the upper ends of upright supports  52  and  54 .  
       FIG. 6  illustrates uprights  44  and  46  assembled onto cross members  16  and  18 , with upper support members  48  and  50  assembled thereon as well.  FIG. 6  further illustrates that shelves  80  are slidably mountable to the slides  56  on uprights  44  and  46 . In the embodiment illustrated, shelves  80  each have a plurality of distending tabs  82 . The tabs  82  are sized to extend out from shelf  80 , and to receive the slide rails  56 . Therefore, opposing pairs of tabs  82  reside on the outer periphery of slide rails  56  to slidably receive the slide rails  56 .  FIG. 7  is a side view of a pair of shelves  80  mounted over slide rails  56  viewed from the direction shown by arrow  90  in  FIG. 6 .  
       FIG. 8  illustrates one embodiment for packing a plurality of shelving assemblies for return shipment in accordance with one embodiment of the present invention.  FIG. 8  is a front view of a shelving assembly taken in the direction illustrated by arrow  92  in  FIG. 6 , wherein the shelving assembly is packed for return shipment.  FIG. 8  shows cross member  16  along with terminals  20  and  22 . The terminals  20  and  22  each have an upright assembly  44  and  46  inserted therein as shown in  FIG. 6 . However, rather than having shelves mounted on slide rails  56 , other upright assemblies  44  or  46  are assembled onto cross member  16  (and the corresponding cross member  18 , not shown) such that the slide rails  56  nest relative to one another. Of course, it will be noted that uprights  44  and  46  may be identical to one another and they are simply numbered with two different designation numerals for the sake of the present description. However, since they are identically sized, they can simply be placed, in pairs, across members  16  and  18  with their corresponding slide rails  56  nesting relative to one another as shown in  FIG. 8 . In this way, a large number of uprights  44  and  46  can be packed onto a single pallet for shipment.  
      It will, of course, be noted that in accordance with another embodiment, a shelving assembly such as that shown in  FIG. 6  can be maintained in tact and a plurality of shelves can be mounted on top of each pair of slide rails  56 . In this way, shelves  80  from a plurality of different shelving assemblies can be packed into a single shelving assembly, again for return shipment.  
       FIG. 9  shows an exploded view of another embodiment of the shelving assembly constructed in accordance with the present disclosure. The shelving assembly, indicated generally at  110 , includes a base member  112  having decking slats  114  and laterally oriented supports  116 . In the example, the laterally oriented supports  116  each include upper and lower supports  118 ,  120  connected together with a set of attachment bars  122 . This configuration provides for strong yet lighter-weight laterally oriented supports  116 . The each end of the laterally oriented supports  116  includes an upright receiving terminal  124 . The laterally oriented supports  116  are connected together with a pair of cross members  126  disposed on each end of the supports  116 .  
      The cross members  126  each include an upper cross support  128 , and each upper cross support  128  includes an open channel  130  extending at least part of the distance along the length of the support  128 . The example includes the channels  130  extending along the entire length of the cross support  128  and having a pair of stops  132  disposed in a middle region of the support  128 . The cross members  126  in the example also include a pair of standoffs  134  attached to the cross supports  128  and terminating at the receiving terminals  124 . The standoffs  134  each include a standoff support  136  extending generally perpendicular to the cross supports  128  and then formed into feet  138 . The feet  138  generally parallel to the cross support  128  and then are formed upwardly at offset portion  140  and terminate at receiving terminal  124 . The standoffs  134  are formed in such a way so that if the feet  138  are in contact with the ground or floor, and so that the cross supports are generally parallel with the plane of the ground or floor, the receiving terminals  124  and laterally oriented supports  116  will not be in contact with the ground. The feet  138  can also include an attached support member  142  that is also connected to the underside of a decking slat  114 . As indicated in the example, the stops  132  are positioned just inside of the standoff supports  136  along the cross supports  128 .  
      The construction of the base member  112  permits nesting and interlocking of several base members, as indicated in  FIG. 10 .  FIG. 10  shows a set of two stacked base members  112   a  and  112   b . In the example shown, the standoffs  134   a , and more specifically the feet  138   a , of base member  112   a  are disposed within channel  130   b  in cross support  128   b  of base member  112   b . When the base members  112   a  and  112   b  are nested as shown, the stops  132   b  prevent the standoffs  136  from moving along the length of the channel  130   b . As such, the base members  112   a  and  112   b  are interlocked to prevent lateral movement relative to one another.  
       FIG. 9  also shows upstanding walls  144 ,  145  each including two wall segments, i.e., lower wall segments  146  and upper wall segments  148 . Of course, any number of one or more wall segments can be used to make up an upstanding wall. Lower wall segments  146  each include two upright supports  150 . Upper wall segments  148  also each include two upright supports  152 . The upright supports  148  and  150  in each wall segment are connected together along the length of the upright supports with a plurality of spaced-apart slide rails  153  to form the wall segments  146 ,  148 . As shown in the example, upright supports  150  are adapted to mate with receiving terminals  124 . In the example, the terminals  124  are sized to receive upright supports  150 . Of course the upright supports  150  could be sized to receive terminals  124  or otherwise be removably attachable to terminals  124 .  
       FIG. 11  shows an example cross-section view of upright receiving terminal  124  of  FIG. 9 . The upright receiving terminal  124  of the example includes a peripheral member  141  and an attached inner sleeve  143 . The inner sleeves  143  are adapted to receive the upright supports  150  from upright walls  144 ,  145 , and the peripheral member  141  are adapted to protect the structural integrity of the inner sleeves  143  in case of damage to the terminals  124 .  
      Also shown in the example of  FIG. 9 , upright supports  150  in the lower wall segments  146  are adapted to mate with upright supports  152  in the upper wall segments  148 . The upright supports  150  in the example also include posts  154  having a diameter generally smaller than the diameter of the upright supports  152  of upper wall segments  148 . The upright supports  152  are sized to receive posts  154 . Of course, the upright supports  150 ,  152  could otherwise be constructed to mate with each other.  
      In the example shown, the wall segments  144 ,  145  are connected together with removable trusses  156  (shown in  FIG. 12 ). The removable trusses  156  are attached to the upright supports  148 ,  150  with fasteners such as bolts or securing pins. Each side of the wall segments  144 ,  145  includes two crossed trusses  156 , as shown in the example. In the example shown in  FIG. 9 , the lower wall segments also each include a pair of crosses and permanent trusses  158 . In the examples shown, removable trusses  156  and permanent trusses  158  are used to maintain the structural integrity of the upstanding walls  144 ,  145 . Other mechanical support structures can be used, including braces  48  and  50  and pivotal supports  60  and  62  shown in  FIGS. 5 and 6 .  
      As shown in  FIG. 9 , Shelves  80  are adapted to be removably connected to the upright walls  144 ,  145  at the slide rails  153  in a manner similar to that shown with respect to  FIG. 6  and discussed above. In one embodiment, a standard assembly  110  includes three shelves  80 , but more or fewer could be used as well.  
       FIG. 12  shows a system of shelving assemblies prepared for return shipment.  FIG. 12  is a front view of a shelving assembly  110  taken in the direction illustrated by arrow  160  in  FIG. 9 . The system includes a plurality of dissembled shelving assemblies are packed into one shelving assembly  110  that is left assembled. In the embodiment shown, two disassembled shelving assemblies are packed into the assemble one. In one embodiment, three or four disassembled shelving assemblies are packed into a single assembled one. Thus, in this embodiment, four or five shelving assemblies can be packed for return shipping into the space of one assembled unit. Of course, other amounts are possible.  
      In the example shown, the base unit  112   a  and upstanding walls  144   a ,  145   a  of a first shelving assembly  110  are left assembled. The base units  112   b ,  112   c  and wall segments from the other two shelving units are disassembled. The three base units  112   a ,  112   b ,  112   c  are stacked and interlocked in a manner shown in  FIG. 10 . The removable trusses  156  of the shelving unit  110  can be temporarily removed while the system is packed. The upright supports  150  of wall segments  146   b ,  146   c , and upright supports  152  of wall segments  148   b ,  148   c  are fit within the channels  130  of base member  112   a . The slide rails  153  are spaced-apart such that a plurality of shelves  80   b ,  80   c  from disassembled units can be stacked on the shelves  80   a  connected to the upstanding walls  144 ,  145 . The removable trusses  156   b ,  156   c  can be stored on the base member  112   a . Once the disassembled parts are stored in the shelving assembly  110 , the removable trusses  156  of the shelving assembly can be reattached to provide for extra support.  
      In one embodiment, the base of the shelving assembly is sized such that two units can sit side-by-side on a standard trailer. For instance, in one embodiment, the base is approximately 40 inches by 48 inches in size. In another embodiment, the base is sized to just fit over a standard pallet of 40 inches by 48 inches in size. The present invention has now been described with reference to several embodiments. The foregoing detailed description and examples have been given for clarity of understanding only. Those skilled in the art will recognize that many changes can be made in the described embodiments without departing from the scope and spirit of the invention. Thus, the scope of the present invention should not be limited to the exact details and structures described herein, but rather by the appended claims and equivalents.