Patent Publication Number: US-9840363-B2

Title: Adjustable suspended roll packaging system

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to crate packaging systems, and more particularly, to an adjustable suspended roll packaging systems for storing and shipping large rolls of wound sheet material, such as fabric or plastic, which are carried on elongated cores. 
     2. Description of Related Art 
     In various manufacture industries, sheet material such as fabric is often shipped in elongated cylindrical rolls utilizing a supporting elongated core. This is also true for the shipping of plastic film and other such materials that can be wound around an elongated core. Difficulty arises from the material handling viewpoint in that the sizes of the material being shipped can vary in the length of the cores, as well as the width. The variations in the material sizes generally depend upon the particular requirements of the customer and thus require custom packaging solutions for a given roll. 
     The prior art largely teaches systems in which the elongated material rolls are shipped on pallets having fixed dimensions. The rolls are positioned in end plates having a central opening for receiving the elongated cores. The end plates are secured to the pallets at pre-defined locations, and are not adjustable or repositionable. Accordingly, since the material rolls often vary in length, different sizes of pallets are used to ship the material rolls and a large quantity of different size pallets must be kept in inventory. 
     The use of pallets having various sizes is inconvenient and expensive. To accommodate for the various sizes of rolls which may be required to be shipped, every warehouse may have over 50 different types of pallets on hand having various widths and lengths with numerous quantities of each type of pallet. Accordingly, there is an excessive amount of money and storage space tied up in pallets which are on hand solely for a particular size shipping job which may or may not be demanded by a customer. 
     Some efforts have been made in the prior art to provide adjustability to the material roll packaging systems to reduce this problem. However, these systems lack durability and/or ease of use in the connections used to secure the end plates. As such, the systems are cumbersome and require multiple people working in concert to adjust the components. Further, impacts sustained during the normal shipping process can lead to a failure of the packaging system and damage to the material roll. 
     Accordingly, it is an object of the present invention to provide an adjustable packaging system for suspending material rolls which is easily adjustable by a single person to accommodate different roll lengths, as well as having sufficiently durable construction and arrangement able to survive normal impacts sustained during shipping. 
     SUMMARY OF THE INVENTION 
     The above objectives are accomplished according to the present invention by providing an adjustable suspended roll packaging system comprising a base platform; a plurality of lower rail members are carried by an upper surface of the base platform; a first end plate engages the lower rail members; a second end plate engages the lower rail members in an opposing laterally spaced arrangement with the first end plate; a series of lower positioning teeth are formed in each of the lower rail members; a series of complementary lower connecting teeth are included on each of the first and second end plates engage the lower positioning teeth of the lower rail members securing the first and second end plates to the lower rail members; a plurality of upper rail members are carried by the first and second end plates; a series of upper positioning teeth are formed in each of the upper rail members; a series of complementary upper connecting teeth are included on each of the first and second end plates engaging the upper positioning teeth of the upper rail members securing the first and second end plates to the upper rail members; and, wherein the series of upper and lower connecting teeth provide for the first and second end plates to be repositionable along at least a portion of the upper and lower rail members to adjust the spacing between the first and second end plates. 
     In a further advantageous embodiment, the upper rail members extend from the first end plate to the second end plate and interconnect an upper edge portion on each of the first and second end plates. 
     In a further advantageous embodiment, the upper rail members extend parallel with the lower rail members. 
     In a further advantageous embodiment, the upper positioning teeth on the upper rail members extend along the length of upper rail members from a first distal end portion to a second distal end portion. 
     In a further advantageous embodiment, a plurality of upper slots are disposed in an upper edge portion on each of the first and second end plates, and the upper connecting teeth disposed in the upper slots, wherein the upper rail members are received in the upper slots so that the upper positioning teeth of the upper rail members engage the upper connecting teeth in the upper slots in interlocking engagement. 
     In a further advantageous embodiment, the upper rail members include upper positioning teeth disposed on opposite side surfaces, and the upper slots include upper connecting teeth on opposing side surfaces so that a first side surface of the upper slots engage with a first side surface of the upper rail members in interlocking engagement, and a second side surface of the upper slots engage with a second side surface of the upper rail members in interlocking engagement. 
     In a further advantageous embodiment, the lower rail members extend from the first end plate to the second end plate and interconnect a lower edge portion on each of the first and second end plates. 
     In a further advantageous embodiment, a notch is included in each lower corner of the first and second end plates receiving the lower rail members, and the lower connecting teeth disposed in the notches engaging the lower positioning teeth of the lower rail members. 
     In a further advantageous embodiment, the lower positioning teeth on the lower rail members extend along the length of lower rail members from a first distal end portion to a second distal end portion. 
     In a further advantageous embodiment, a plurality of lower slots are disposed in a lower edge portion on each of the first and second end plates, and the lower connecting teeth disposed in the lower slots, wherein the lower rail members are received in the lower slots so that the lower positioning teeth of the lower rail members engage the lower connecting teeth in the lower slots in interlocking engagement. 
     In a further advantageous embodiment, the lower rail members include lower positioning teeth disposed on opposite side surfaces, and the lower slots include lower connecting teeth on opposing side surfaces so that a first side surface of the lower slots engage with a first side surface of the lower rail members in interlocking engagement, and a second side surface of the lower slots engage with a second side surface of the lower rail members in interlocking engagement. 
     In a further advantageous embodiment, a strap slots is disposed in a distal end portion of the lower rail members for receiving a securing strap. 
     In a further advantageous embodiment, each tooth of the upper and lower connecting teeth and the upper and lower positioning teeth has two inclined engaging surfaces intersecting at a peak in which opposing tooth engaging surfaces are angled at approximately 60 degrees relative to each other. 
     In a further advantageous embodiment, the series of lower positioning teeth are formed in the upper surface of the base platform. Further, at least one connecting tooth is disposed on a lower edge surface of each the first and second end plates engaging the lower positioning teeth on the base platform in interlocking engagement. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The construction designed to carry out the invention will hereinafter be described, together with other features thereof. The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein: 
         FIGS. 1A-1E  show various aspects of a first embodiment of an adjustable suspended roll packaging system according to the present invention; 
         FIGS. 2A-2C  show various aspects of a second embodiment of an adjustable suspended roll packaging system according to the present invention; 
         FIG. 3  shows a perspective view of a third embodiment of an adjustable suspended roll packaging system according to the present invention; 
         FIG. 4  shows a perspective view of a forth embodiment of an adjustable suspended roll packaging system according to the present invention; 
         FIGS. 5A-5D  show various aspects of a fifth embodiment of an adjustable suspended roll packaging system according to the present invention; and, 
         FIGS. 6A-6B  show various aspects of a sixth embodiment of an adjustable suspended roll packaging system according to the present invention 
     
    
    
     It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can meet certain other objectives. Each objective may not apply equally, in all its respects, to every aspect of this invention. As such, the preceding objects can be viewed in the alternative with respect to any one aspect of this invention. These and other objects and features of the invention will become more fully apparent when the following detailed description is read in conjunction with the accompanying figures and examples. However, it is to be understood that both the foregoing summary of the invention and the following detailed description are of preferred embodiments and not restrictive of the invention or other alternate embodiments of the invention. In particular, while the invention is described herein with reference to specific embodiments, it will be appreciated that the description is illustrative of the invention and is not constructed as limiting of the invention. 
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     With reference to the drawings, the invention will now be described in more detail. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are herein described. 
     Unless specifically stated, terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. 
     Furthermore, although items, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. 
     Referring to  FIGS. 1A-1E , a first embodiment of an adjustable suspended roll packaging system is shown. The packing system includes a base platform, designated generally as  10 . Base platform  10  includes a series of base support beams  12  carrying an arrangement of floor boards  14 . Preferably, base platform  10  is arranged to allow for fork lift engagement by including recesses  16  in base support beams  12 . 
     A plurality of lower rail members  18  are carried on an upper surface  20  of floor boards  14  of base platform  10 . Lower rail members  18  are secured to upper surface  20  of base platform  10 . A series of lower positioning teeth  22  are formed into each of lower rail members  18 . In the illustrated embodiment, lower positioning teeth  22  are define by a series of grooves and ridges formed into lower rail members  18  and extending along at least a distal end portion  22   a  of each of rail member  18 . In the embodiment of  FIGS. 1A-1E , lower positioning teeth  22  are disposed only along an inner side surface  23  of rail members  18 . 
     Referring to  FIGS. 1A-1E , a first end plate  24  and a second end plate  26  engage both of lower rail members  18 . First and second end plates  24 ,  26  are carried in an opposing laterally spaced arrangement. In the illustrated embodiment, first and second end plates  24 ,  26  are positioned within distal end portion  22   a  for engaging lower positioning teeth  22  of lower rail members  18 . An elongated core (not pictured) that carries the material roll (not pictured) is positioned within central opening  28  in each of opposing end plates  24  and  26  to suspend the material over floor boards  14 . 
     A series of lower connecting teeth  30  are included on each of first and second end plates  24  and  26 . In the embodiment of  FIGS. 1A-1E , lower connecting teeth  30  are disposed at the lower corners, designated generally as  31 , on each of first and second end plates  24 ,  26  and arranged facing outward toward lower rail members  18 . Referring to  FIG. 1D , a notch, designated generally as  33 , is carved out of each lower corner  31  of first and second end plates  24 ,  26 , which receives lower rail members  18 . Lower connecting teeth  30  are recessed in the notches and engage lower positioning teeth  22  of lower rail members  18 . In the illustrated embodiment, lower rail members  18  extend between and interconnect lower corners of opposing first and second end plates  24 ,  26 . 
     Referring to  FIGS. 5A and 6A , in a further embodiment, an overhang  32  is formed by each notch in the lower corners  31  of first and second end plates  24 ,  26 . In the embodiments shown in  FIGS. 5A and 6A , overhang  32  can be constructed and arranged to engage a top side  37  of lower rail members  18  to assist in stabilizing end plates  24  and  26  in position relative to lower rail members  18 . 
     Referring to  FIGS. 1A-1E , lower connecting teeth  30  are complementary in shape to and adapted for engaging lower positioning teeth  22  to secure first and second end plates  24  and  26  in selected position along distal end portions  22   a  of lower rail members  18 . Preferably, lower connecting teeth  30  include a plurality of teeth projected from each lower corner of first and second end plates  24  and  26 . However, the arrangement can be accomplished with a single lower connecting tooth on each lower corner of first and second end plates  24 ,  26 . First and second end plates  24  and  26  can be positioned by sliding the end plates vertically downward so that lower connecting teeth  30  engage with lower positioning teeth  22 . Accordingly, repositioning first and second end plates  24 ,  26  simply requires raising the end plates up again, selecting the new position along distal end portions  22   a  of lower rail members  18  and lowering the end plates back down into interlocking engagement. The interlocking arrangement of the engaging complementary teeth  22  and  30  does not require any tools or other connecting members such as screws and the like. 
     In the illustrated embodiment of  FIGS. 1A-1E , a plurality of upper rail members  34  are carried by first and second end plates  24  and  26  to reinforce an upper edge portion  39  of first and second end plates  24 ,  26 . As illustrated, upper rail members  34  are arranged to extend along the length of base platform  10  generally parallel with lower rail members  18 . Upper rail members extend from first end plate  24  to second end plate  26  and interconnect upper edge portions  39  on each of first and second end plates  24 ,  26 . A series of upper positioning teeth  36  are formed in each of upper rail members  34 . As with lower positioning teeth  22 , upper positioning teeth  36  are define by a series of grooves and ridges extending along at least a portion of each of upper rail members  34 . In the illustrate embodiment, upper positioning teeth  36  are disposed along a distal end portion  36   a  in a complementary arrangement to lower rail members  18  and lower positioning teeth  22 . 
     Each of upper rail members  34  are received into a respective upper slots  38  disposed along an upper edge portion  39  of first and second end plates  24  and  26 . A series of complementary upper connecting teeth  40  are disposed in upper slots  38  for engaging upper positioning teeth  36  to secure first and second end plates  24  and  26  in position along distal end portion  36   a  of upper rail members  34  in interlocking engagement. 
     In the embodiment of  FIGS. 1A-1E , upper positioning teeth  36  are preferably disposed along both vertical opposite side surfaces of upper rail members  34 . Upper slots  38  include complementary upper connecting teeth  40  on opposing side surfaces so that a first side surface of upper slots  38  engage with a first side surface of upper rail members  34  in interlocking engagement, and a second side surface of upper slots  38  engage with a second side surface of upper rail members  34  in interlocking engagement. 
     Upper connecting teeth  40  are complementary in shape to and adapted for engaging upper positioning teeth  36  to secure the upper edge portion  39  of first and second end plates  24  and  26  in selected position along distal end portions  36   a  of upper rail members  34 . Preferably, upper connecting teeth  40  include at least two teeth projected from vertical opposing side surfaces within each of upper slots  38  for engaging complementary upper positioning teeth on the vertical side surface of each upper rail member  34 . First and second end plates  24  and  26  can be positioned relative to upper rail members  34  by sliding rail members  34  vertically upward out of upper slots  38 , repositioning first and second end plates relative to lower rail members  18  as detailed above, and then lowering upper rail members  34  back into interlocking engagement within upper slots  38  so that upper connecting teeth  40  engage with upper positioning teeth  36 . The interlocking arrangement of the engaging complementary teeth  36  and  40  does not require any tools or other connecting members such as screws and the like. 
     Referring to  FIGS. 2A-2C , in this alternative embodiment of the packaging system, lower rail members  18  include lower positioning teeth  22  disposed on both vertical side surfaces to increase interlocking engagement with first and second end plates  24 ,  26 . Accordingly, first and second end plates  24  and  26  now each include a plurality of lower slots  44  along a lower edge portion  45  for receiving lower rail members  18  in the same arrangement as upper rail members  34  are received into upper slots  38  in the embodiment of  FIGS. 1A-1E . 
     In the illustrated embodiment of  FIGS. 2A-2C , a series of complementary lower connecting teeth  30  are disposed on opposing side surfaces of lower slots  44  for engaging lower positioning teeth  22  on both sides of lower rail members  18  to secure first and second end plates  24  and  26  in position along lower rail members  18 . Thus, by engaging both vertical side surfaces of lower rail members  18  with interlocking teeth, the interlocking engagement is effectively doubled. 
     Referring to  FIG. 2A , in the illustrated embodiment, lower rail members  18  extend across upper surface  20  from first end plate  24  to said second end plate  26  and interconnect lower edge portion  45  on each of first and second end plates  24 ,  26 . 
     Referring to  FIG. 3 , an alternative embodiment of the packaging system is illustrated in which lower rail members  18  are segmented into a plurality of smaller portion for cooperating with first and second end plates  24  and  26  in the same interlocking engagement described above in the embodiment of  FIGS. 2A-2C . In the embodiment of  FIG. 3 , each of the smaller lower rail members  18  is secured to base platform  10 . Lower rail members  18  again include a series of lower positioning teeth  22  extending along both vertical side surfaces of each rail member  18 . In the illustrated embodiment of  FIG. 3 , first and second end plates  24  and  26  again each include lower slots  44  along lower edge portions  45  for receiving lower rail members  18  in the same arrangement detailed above for  FIGS. 2A-2C . A series of complementary lower connecting teeth  30  are disposed in lower slots  44  for engaging lower positioning teeth  22  to secure first and second end plates  24  and  26  in position along lower rail members  18 . Thus, by engaging both vertical side surfaces of lower rail members  18  with interlocking teeth, the interlocking engagement is effectively doubled, but without lower rail members  18  extending between first and second end plates  24 ,  26  along the length of base platform  10  as may be required to accommodate certain material rolls, as well as reducing some material costs associated with rail members  18 . 
     Referring to  FIG. 4 , this alternative embodiment of the packaging system is shown that is largely similar in arrangement to the embodiment of  FIGS. 2A-2C , with the exception that lower positioning teeth  22  of lower rail members  18  and upper positioning teeth  36  of upper rail members  34  extended entirely along the length of both vertical side surface on the lower and upper rail members  18 ,  34  from a first distal end portion to a second distal end portion. Accordingly, upper and lower slots  38  and  44  of first and second end plates  24  and  26  are repositionable for interlocking engagement at any location along the length of upper and lower rail members  34  and  18  to provide maximum flexibility in accommodating various material roll lengths. 
     Referring to  FIGS. 5A-5D , a further embodiment of the packaging system is shown having an arrangement similar to the embodiment of  FIGS. 1A-1E , except that upper rail members  34  illustrate upper positioning teeth  36  disposed along a single vertical side surfaces of upper rail members  34 . As best shown in  FIG. 5B , upper slots  38  of first and second end plates  24 ,  26  includes complementary upper connecting teeth  40  disposed on only one side surfaces of the slot for engaging upper positioning teeth  36  of upper rail members  36  in interlocking engagement. 
     Referring to  FIG. 5A , lower rail members  18  engage first and second end plates in the same basic manner as described above for  FIGS. 1A-1E . As such, lower connecting teeth  30  on each of first and second end plates  24  and are disposed at the lower corners, designated generally as  31 , and arranged facing outward toward lower rail members  18 . Notches  33  receives lower rail members  18 . Lower connecting teeth  30  are recessed in the notches and engage lower positioning teeth  22  of lower rail members  18 . In the illustrated embodiment, lower rail members  18  extend between and interconnect lower corners of opposing first and second end plates  24 ,  26 . Overhang  32  engages top side  37  of lower rail members  18  to assist in stabilizing end plates  24  and  26  in position relative to lower rail members  18 . 
     Referring to  FIGS. 5A and 5C , distal end portions  22   a  of lower rail members  18  include a strap slot  46  for receiving a securing strap. Additionally, in the illustrated embodiment of  FIGS. 5A and 5D , a bull nose banding notch  48  is disposed in distal end portion  36   a  of upper rail members  34 . Accordingly, a securing strap can be passed though strap slot  46  in lower rail members  18  and over upper rail members  34  at bull nose banding notch  48  to interconnect upper and lower rail members  18 ,  34  to resist separation of the rail members from first and second end plates  24 ,  26 . Securing strap  46  and bull nose banding notch  48  can be applied and used in each embodiment detailed herein as desired to improve resilience of the packaging system. 
     Referring to  FIG. 5D , for each of the embodiments detailed herein, each tooth of upper and lower connecting teeth  40 ,  30  and upper and lower positioning teeth  36 ,  22  has two inclined engaging surfaces  50   a  and  50   b  intersecting at a peak in which opposing tooth engaging surfaces  50   a  and  50   b  are angled at approximately 60 degrees relative to each other, designated generally as angle “A”. 
     Referring to  FIGS. 6A-6B , a further embodiment of the packaging system is shown having an arrangement similar to the embodiment of  FIGS. 5A-5D , except that lower positioning teeth  22  are moved from lower rail members  18  to floor boards  14  of base platform  10 . In the illustrated embodiment, a series of lower positioning teeth  22  are formed in an upper surface of base platform  10  on floor boards  14 . At least one connecting tooth  30  is disposed on a lower edge surface, designated generally as  52  ( FIG. 6B ), of each of first and second end plates  24 ,  26  engaging lower positioning teeth  22  on floor boards  14  of base platform  10  in interlocking engagement. 
     As noted above, a notch  33  is included in each lower corner of first and second end plates  24 ,  26  receiving lower rail members  18  so that overhang  32  engages top side  37  of lower rail members  18  to assist in stabilizing end plates  24  and  26  in position relative to lower rail members  18 . While no lower positioning teeth  22  are disposed in notch  33  for engaging lower rail members  18 , the arrangements described in the above alternative embodiments for interconnecting first and second end plates  24 ,  26  with lower rail members  18  can be used in combination with the arrangement of  FIGS. 6A-6B  in which lower positioning teeth  22  are included on floor boards  14  and lower connecting teeth  30  are also included on lower edge surface  52 . 
     While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein.