Patent Publication Number: US-2020290767-A1

Title: Top cap

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present invention claims priority to and the benefit of U.S. Provisional Patent Application No. 62/817,692 filed Mar. 13, 2019, the contents of which are incorporated herein by reference. 
    
    
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     N/A 
     FIELD OF THE INVENTION 
     The present invention is generally directed to an improved top cap without a full perimeter lip for use in moving stacked totes on a transport system such as a pallet; and more particularly to a top cap having a plurality of puck shaped structures projecting downward to contain stacks of totes without a conventional perimeter lip. 
     DESCRIPTION OF THE PRIOR ART 
     Molded plastic top caps are often used in combination with pallets and other transport apparatus to provide unitized transport systems to move various loads. The loads can include stacks of containers or totes such as those shown in  FIG. 1 . Straps can be tightened around the pallet and top cap to keep the load secure. In most, if not all such instances, the top cap includes a downwardly extending, continuous lip around the entire perimeter of the top cap to contain the stacks of totes on the pallet. This, in part, can limit the number of transport systems that can be loaded into a trailer of a truck for shipping. 
     The present invention provides a top cap that can be used in a transport system having a reduced footprint such that it is possible to fit additional transport systems in a standard trailer of a truck. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to an improved top cap having a plurality of puck shaped projections for containing stacks of totes on a pallet. The projections allows for removal of a continuous lip around the entire perimeter of the top cap—thus enabling creation of a transport system having a smaller footprint (than the conventional top cap allowed for). 
     In accordance with one aspect of the present invention, a top cap is provided comprising a generally rectangular upper surface having a first side edge, a second side edge opposing the first side edge, a first end edge and a second end edge opposing the first end edge. The upper surface of the top cap includes a plurality of tote contacting projections extending downwardly from the upper surface. The projections are in a pattern configured to enable each projection to contact a corner portion of a tote when the top cap is placed on a plurality of totes. In some instances, the top cap can include additional projections positioned to contact the totes at other (non-corner) locations. 
     The top cap can also include a lower surface opposing the upper surface. A plurality of ribs can extend downward from the lower surface. The plurality of ribs can include a first portion extending in a parallel formation from the first side edge to the second side edge. A second portion of the plurality of ribs can extend in a parallel formation from the first end edge to the second end edge. 
     The plurality of tote contacting projections are configured to extend downward further than a lower edge of the plurality of ribs. In this regard, the tote contacting projections include a contact portion below the lower edge of the plurality of ribs that is generally cylindrical (in practice, each of the plurality of tote contacting projections has a generally hollow conical shape). The corners of the totes are typically rounded or arcuate, and the contact portion is configured to engage an inner corner of the tote. Preferably, the contacting portion has the same radius as the corner. 
     The top cap is configured so that it does not include a continuous lip around its periphery. In one configuration, each of the first end edge and the second end edge includes a downwardly extending lip while the first side edge and the second side edge are lipless. 
     The top cap can also include a plurality of downwardly extending depressions and/or upwardly extending projections in the upper surface. The depressions/projections can be configured to mate with a footprint of one or more other transportation systems that may be stacked on the top cap. 
     In accordance with another aspect of the invention, a top cap for use in combination with a transport system is provided. The top cap comprises a rectangular layer of material having a first side edge, a second side edge, a first end edge, a second end edge, an upper surface and a lower surface. The layer of material can include a plurality of ribs extending downward from the lower surface. Additionally, the top cap includes a plurality of spaced apart projections of the layer of material for contacting totes when the top cap is placed on stacks of totes. If the top cap includes lower ribs, the projections need to extend downward below a lower edge of the ribs. 
     Each of the projections has a generally cylindrical or slightly conical shape. Additionally, each of the projections includes a puck shaped portion that extends beyond the lower edges of the ribs. The puck shaped portion is configured to engage a portion of the top of a tote. 
     The plurality of ribs can include a first series of parallel ribs extending between the first side edge and the second side edge and a second series of parallel ribs extending from the first end edge to the second end edge. The first series of ribs are perpendicular to the second series of ribs. The ribs can be spaced closely or further apart in different portions of the lower surface of the top cap. 
     Each of the projections is positioned to contact a top of a tote when the top cap is placed on a plurality of stacks of totes. In particular, each projection is configured to contact an inner radius of a corner of the tote. The projections can be positioned in a pattern to contact twelve stacks of totes fitting on a pallet. The projections can be also be positioned for other tote sizes, e.g., four, six, etc., that fit on the pallet. 
     The top caps can be formed from a molded plastic. Other similar or suitable materials can also be used. The top cap can be a single piece or can be composed of multiple pieces connected to each other. 
     Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following Figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view of a known top cap on top of a plurality of totes stacked on a pallet; 
         FIG. 2A  is a shaded perspective views of a top cap in accordance with the present invention; 
         FIG. 2B  is a wireframe perspective view of the top cap of  FIG. 2A ; 
         FIG. 3A  is a shaded top plan view of the top cap of  FIG. 2A ; 
         FIG. 3B  is a wireframe top plan view of the top cap of  FIG. 2A  with the top edges of ribs extending from a bottom surface of the top cap visible; 
         FIG. 4A  is a shaded bottom perspective view of the top cap of  FIG. 2A ; 
         FIG. 4B  is a wireframe bottom perspective view of the top cap of  FIG. 2A ; 
         FIG. 5A  is a shaded bottom plan view of the top cap of  FIG. 2A ; 
         FIG. 5B  is a wireframe bottom plan view of the top cap of  FIG. 2A ; 
         FIG. 6  is an enlarged wireframe bottom perspective view of a portion of the top cap of  FIG. 2A ; 
         FIG. 7A  is a shaded side plan view of the top cap of  FIG. 2A ; 
         FIG. 7B  is a wireframe side plan view of the top cap of  FIG. 2A ; 
         FIG. 8A  is a shaded end plan view of the top cap of  FIG. 2A ; 
         FIG. 8B  is a wireframe end plan view of the top cap of  FIG. 2A ; 
         FIG. 9  is a perspective view of a puck shaped portion of a contacting projection of the top cap of  FIG. 2A ; 
         FIG. 10  is a schematic view showing placement of the projections of the top cap on top of twelve stacks of totes; 
         FIG. 11  is a schematic view showing placement of the projections of the top cap on top of four stacks of totes; 
         FIG. 12  is a schematic view showing placement of the projections of the top cap on top of six stacks of totes; 
         FIG. 13  is a combined top and bottom perspective view of the top cap of  FIG. 2A ; 
         FIG. 14  is a top plan view of another top cap in accordance with a another aspect of the present invention; 
         FIG. 15  is a top plan view of stacks of totes which are configured for use with the top cap of  FIG. 14 ; 
         FIG. 16  is a perspective view of a plurality of totes of  FIG. 15 . 
     
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. 
     In industrial markets, the common pallet size is 45×48″. This size pallet limits load transport to 26-floor positions in a standard 53′ trailer (i.e., 26 pallets with top caps transport systems per trailer). By adjusting the width down to 44.5″, it is possible to get an additional 2-floor positions per trailer, making 28-floor positions total. 
     Adjusting the width of the pallet down to 44.5″ requires shrinking all the components in the width dimension. The problem with this approach is all the existing 26-position system components presently in the field. That is, backwards compatibility with 26-position components must be maintained. The pallet and totes can accomplish such backwards compatibility using existing design elements. However, the top cap is unique in that it requires a new approach to achieve acceptable containment of the totes. 
     The totes (e.g., such as StakPaks) the top cap contains have a maximum footprint of 45×48″ for 26-floor positions and 44.5×48″ for 28-floor positions. With a maximum width of 44.5″, this leaves no room for a downwardly extending lip on the short sides of the top cap. Instead, the present invention provides a top cap that engages internal surfaces of the totes using a pattern of “puck” shaped features that protrude beneath the top cap. These puck shaped features engage the inner corner radii of the totes in such a way as to prevent them tipping outward toward the long (48″) sides, while not impeding on the totes fill space. The puck pattern is designed to engage different patterns of totes, as shown in  FIGS. 10-12 . 
     As shown in  FIG. 1 , a conventional (prior) transport system  10  includes a pallet  12 , a top cap  14 , and a plurality of stacks of totes  16  between the pallet  10  and the top cap  14 . Straps  18  are provided to secure the top cap  16  and stacks of totes  16  to the pallet  12 . The top cap  14  includes a lip  20  around each of the sides and ends of the top cap  14 . 
     A top cap  22  in accordance with the present invention is shown in  FIGS. 2A  and B. As shown,  FIG. 2A  is a shaded form of an electronic drawing of the top cap and  FIG. 2B  is a wireframe form of the same drawing. [In these—and certain other Figures—additional shading and lines (such as framing lines  11  in  FIG. 2B )—may be present. Applicant intends on preparing formal drawings removing these extra components from the Figures and modifying the specification accordingly (i.e., such as deleting this bracketed explanation).]. 
     The top cap  22  is a layer of material having a generally rectangular shape with a first side edge  24 , an opposing second side edge  26 , a first end edge  28 , and an opposing second end edge  30 . An upper surface  32  (and a corresponding lower surface  38  not shown in  FIGS. 2A  and B) extends between the side and end edges  24 ,  26 ,  28 ,  30 . 
     As evident in the perspective views of  FIGS. 2A  and B, and in the top plan views of  FIGS. 3A  and B, the upper surface  32  of the top cap  22  includes a plurality of spaced apart circular openings  34 . These openings  34  are formed by downward projections of the top cap  22 . The upper surface  32  of the top cap  22  also includes a plurality of depressions  36  having a variety of shapes (the depressions are positioned lower than a plane defined by the remaining portion of the upper surface—such features can also include upward projections from that plane). The depressions  36  are shaped and positioned to mate with the footprint of one or more other transport systems that might be stacked on top of the top cap (e.g., the bottom structure of other pallets, or bulk bins, for example). 
     Referring to  FIGS. 4-6 , the underside of the top cap  22  includes a lower surface  38 , and a plurality of ribs  40  that extend downward from the lower surface  38 . The ribs  40  are generally perpendicular to each other with a plurality of parallel ribs extending between the first side edge  24  and the second side edge  26 , a plurality of parallel ribs extending between the first end edge  28  and the second end edge  30 . The lower edges of the ribs end in or define a plane. 
     In some portions of the bottom of the top cap  22 , the ribs  40  are closer to each other than in other portions of the bottom. Although shown in a particular configuration, the ribs can be other configurations as desired. 
     In addition to the ribs  40 , the top cap  22  includes a plurality of projections  42  extending downward from the lower surface  38 . The projections  42  align with the circular openings  34  on the upper surface  32  of the top cap  22 . The projections  42  are shown having a generally conical (almost cylindrical) outer surface  44  that cuts off at the bottom (while the projections are shown as conical, other shapes can be utilized). 
     As more clearly illustrated in the enlarged view of  FIG. 6  and the side plan views of  FIGS. 7A  and B, the projections  42  extend below the lower edges of the ribs  40 . This leaves a contacting portion  44  of the downward projection  42  exposed to contact the tops of totes when the top cap  22  is placed on top of the stacks of totes  16 . The contacting portion  44  has a puck-like shape. This puck-like shape of the contacting portion  44  is more evident in  FIG. 9  which shows only the contacting portion  44 . The contacting portion  44  can have a complete or partial opening on the bottom—i.e., contacting side, of the contacting portion  44 . 
     The projections  42  shown are hollow. However, if additional support is needed in the projection, it may be possible to add internal structure (either an additional piece, or molded in ribs, etc.) to the projections  42 . 
     As also evident in  FIGS. 7A  and B, as well as in  FIGS. 8A  and B, the top cap  22  does not include a downwardly extending lip along the first and second side edges  24 ,  26 . While the top cap  22  is lipless along the first and second side edges, in the embodiment shown, a downwardly extending lip  46  does extend from the first end edge  28  and the second end edge  30 . That is, only the end edges have a lip. The lips  46  are not continuous about the periphery of the top cap  22 . 
     The projections  42  in the top cap  22  are spaced from each other, and are configured in a pattern for proper placement when the top cap  22  is positioned on various stacks of totes  16 . The projections  42  are designed to place pressure at key locations on the stacks of totes  16  to contain the totes  16  in a unitized system with a pallet and straps. 
     Referring to  FIGS. 10, 11 and 12 , various configurations are provided for different sized totes.  FIG. 10  illustrate placement of the projections  42  on twelve stacks of totes  16  positioned in a 3×4 matrix.  FIG. 11  shows placement of the projections  42  a 2×3 matrix and  FIG. 12  shows placement on a 2×3 matrix. 
     As evident in  FIGS. 10-12 , in each tote configuration, some of the projections  42  align with a corner of the top of a tote. In the examples shown, the corners of the totes are rounded or arcuate. The projection is configured to have a radius that matches the radius of the arcuate corner. 
       FIG. 14  discloses an alternate embodiment of a top cap  50 . The top cap  50  is designed to be placed on containers  52  having various locking features  54 ,  56 ,  58 ,  60  as shown in  FIGS. 15 and 16 . The top cap  50  includes indentations and/or projections  62 ,  64 ,  66 ,  68  that mate with the locking features  54 ,  56 ,  58 ,  60 . 
     The top caps are preferably formed from a mold plastic or other similar or suitable materials. For example, the top cap can be made in a thermoforming process. 
     In some instances, the top cap can have corrugations or a pattern of (smaller) cones or other structures instead of ribs extending from the lower surface. 
     Directional terms (such as: up, downward, right, left, etc.) are used herein to describe the top cap as it is typically positioned when in use and/or as shown in one or more of the Figures. Such terms are not meant to limit the scope of the invention to being in such positions. 
     Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood within the scope of the appended claims the invention may be protected otherwise than as specifically described.