Patent Publication Number: US-8534969-B2

Title: Apparatus and method for packing concentrated mass loads for transport by container, box truck and van trailer

Description:
This application claims priority on U.S. Provisional patent application No. 61/381,357 filed Sep. 9, 2010 and U.S. Provisional patent application No. 61/417,565 filed Nov. 29, 2010, incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to the transportation of concentrated mass loads by container, box truck and van trailer and apparatus for use in transporting concentrated mass loads by container, box truck and van trailer. The invention has application to the transportation of, inter alia, coils and reels. 
     BACKGROUND OF THE INVENTION 
     It is known to ship steel coils by container, box truck and van trailer. However, because of the very large mass associated with a steel coil, and the localized nature thereof, known methods for shipping steel coils by container, box truck and van trailer often involve relatively expensive, bulky pallets which are loaded with coils, which are slid or rolled into the cargo area for transport and which spread the load of the coils over the cargo floor. 
     SUMMARY OF THE INVENTION 
     Forming one aspect of the invention is a load equalizing pallet apparatus for transporting a concentrated load and for use with load binders. The load equalizing pallet apparatus comprises: a load equalizing base constructed substantially out of wood, having a periphery and, in use, receiving said load; and a plurality of metal shoes arranged, in use, about the periphery of the base and rigidly engaged thereto, each shoe having a plurality of lugs, the lugs, in use, being engaged by said load binders to couple said load to said pallet. 
     According to another aspect of the invention, the base can be defined by a substantially rectangular lattice of dimensional timbers and the shoes can be arranged one at each corner of said lattice. 
     According to another aspect of the invention, the lattice of dimensional timbers can include a pair of parallel timbers and the ends of said pair of parallel timbers can define the corners of the lattice. 
     According to another aspect of the invention, each end of said pair of parallel timbers can be in receipt of a shoe, the shoe defining a socket which, in use, grippingly receives said each end. 
     According to another aspect of the invention, the shoe can have a pair of lugs which, in use, present upwardly and one or more lugs which, in use, project laterally outwardly from said pallet. 
     The pallet apparatus can be used as part of a method which forms another aspect of the invention. The method comprises the steps of: placing the pallet apparatus in a container, box truck or van trailer; placing said load on the pallet apparatus; securing the load to the pallet apparatus using load binding straps; and securing the pallet apparatus against movement. 
     According to another aspect of the invention, the pallet apparatus can be placed in the container and secured against movement by blocking the base inside the container using a framework of dimensional lumber constructed on the container floor. 
     According to another aspect of the invention, the pallet apparatus can be placed in the van trailer and secured against movement by nailing bracing to the floor of the van trailer. 
     The pallet apparatus can, in another aspect of the invention, form part of a shipping apparatus which includes, in addition to the pallet apparatus, a shelf apparatus defining, in use, a load-receiving surface disposed above the pallet apparatus. 
     According to another aspect of the invention, the shelf apparatus can comprise: a leg for each shoe, the leg being received, in use, in one of the laterally-outwardly projecting lugs of said each shoe. 
     According to another aspect of the invention, the shelf can comprise a pair of standards, each standard being defined in part by a pair of said legs, the legs of said each standard being rigidly secured to one another. 
     According to another aspect of the invention, the shelf apparatus can comprise one or more deck structures, each of said one or more deck structures spanning between and coupled to the pair of standards to space the standards apart. 
     Other advantages of the present invention will become evident upon review of the accompanying detailed description and drawings, the latter being briefly described hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a perspective view of a load equalizing pallet apparatus according to an exemplary embodiment of the invention; 
         FIG. 2  is an enlarged view of encircled area  2  of  FIG. 1 ; 
         FIG. 3  is a view of the structure of  FIG. 2  from another vantage point and with the load-equalizing base removed, for clarity; 
         FIG. 4  is a view, similar to  FIG. 1 , of a load equalizing apparatus according to another embodiment; 
         FIG. 5  is an enlarged view of encircled area  5  of  FIG. 4 ; 
         FIG. 6  is a view of the structure of  FIG. 5  from another vantage point and with the load-equalizing base removed, for clarity; 
         FIG. 7  is an enlarged view of a portion of the structure of  FIG. 6 ; 
         FIG. 8  is an enlarged view of another portion of the structure of  FIG. 6   
         FIG. 9  is a perspective view of the structure of  FIG. 1 , with a palletized coil secured thereon by binders; 
         FIG. 10  is an enlarged view of encircled area  10  of  FIG. 9 ; 
         FIG. 11  is, inter alia, a schematic view of the structure of  FIG. 9  positioned in a 40′ shipping container; 
         FIG. 12  is a view of the interior of a shipping container wherein a pair of the structures of  FIG. 9  have been operatively positioned; 
         FIG. 13  is an enlarged view of encircled area  13  of  FIG. 12 ; 
         FIG. 14  is another view of the interior of the shipping container of  FIG. 10 ; 
         FIG. 15  is a view, similar to  FIG. 11 , but as part of a van trailer; 
         FIG. 16  is a view similar to  FIG. 11  and also showing a shelf apparatus bearing a load; 
         FIG. 17  is an exploded view of the structure of  FIG. 16 ; 
         FIG. 18  is a view showing portions of the structure of  FIG. 16  assembled for use; 
         FIG. 19A  is a top plan schematic view of a 40′ container in which four of the load equalizing apparatus are loaded and in operative receipt of reels; 
         FIG. 19B  is a side schematic view of the structure of  FIG. 19A ; 
         FIG. 19C  is an end view of the structure of  FIG. 19A ; 
         FIG. 20A  is an end schematic view of a 53′ container in which five of the load equalizing apparatus are loaded and in operative receipt of reels; 
         FIG. 20B  is a top schematic view of the structure of  FIG. 20A ; 
         FIG. 20C  is a side view of the structure of  FIG. 20A  but wherein one of the load equalizing apparatus in the process of removal; 
         FIG. 21A  is a detail end view, showing a portion of the structure of  FIG. 20A ; 
         FIG. 21B  is a side view of the structure of  FIG. 21A   
         FIG. 22A  is a view, similar to  FIG. 21A  but showing an alternate embodiment; and 
         FIG. 22B  is a side view of the structure of  FIG. 22A . 
     
    
    
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     As mentioned in the description thereof, the FIGURES show two exemplary embodiments of a load equalizing pallet  20  and  20 ′, an exemplary embodiment of a shelf apparatus  22  and various partial, assembly and use views thereof. 
     Turning first to the embodiment of the load equalizing pallet  20  shown in  FIGS. 1-3 , same will be seen to comprise a load equalizing base  24  and a plurality of shoes  25 . 
     The load equalizing base  24  is constructed substantially out of wood and has a periphery. More particularly, base  24  is defined by a generally rectangular lattice of dimensional timbers  26 ,  28 ,  30 ,  32  arranged in two layers  34 , 36  and bolted together where they intersect, the lattice having a periphery with four corners  38 , with the corners  38  being defined by the ends of the outermost pair of parallel timbers  32  in the lower layer  36 . 
     With reference to  FIG. 2  and  FIG. 3 , each shoe  25  will be seen to be defined by a square steel tube  40 , partially closed at one end by a triangular steel plate  42 , and having securely welded thereto, on two adjacent surfaces, a plurality of steel lugs  44 . In two of the perpendicular surfaces of the steel tube  40 , apertures  46  are formed. 
     As seen in  FIG. 1 , the shoes  25  are arranged around the periphery, more particularly, are rigidly secured one at each corner, with each shoe  25  being arranged such that a pair of lugs  44  present upwardly and one or more lugs  44  project laterally outwardly from said pallet apparatus  20 . 
     As best seen in  FIG. 2 , the rigid securement of each shoe  25  involves the placement of shims  48  inside the steel tube  40 , to form a socket  50  which grippingly receives the end of the timber, and driving nails  52  through the apertures  46 , to secure the shims  48  in place and resist movement of the shoe  25  from the timber  32 . 
     The load equalizing pallet  20 ′ of  FIGS. 4-8  is substantially functionally identical to that of  FIGS. 1-3 . However, rather than using the shim/nail arrangement for forming the socket, each shoe  25 ′ is defined by a pair of half-shoes  54 , 56 , which are tightly secured to one-another around the timber by bolts  58 . 
     Turning now to the assembly views of  FIGS. 9 and 10 , it will be understood that these views show the structure of  FIGS. 1-3 , with a concentrated load, namely, a palletized steel coil  60 , positioned upon the base  24 , and a plurality of load binding straps  62  holding the coil  60  to the base  24 . This is the manner in which the apparatus  20  is used in certain of the methods that form part of the invention. 
     With further regard to the methods, reference is now made to  FIG. 11 , which, as mentioned in the BRIEF DESCRIPTION, is a schematic view of the structure of  FIG. 9  operatively positioned in a shipping container  77 . This view shows an interim stage of the container method, i.e. the result of the steps of:
         placing a first load equalizing pallet apparatus  20 A on the floor of the shipping container   placing a palletized coil  60  on the first load equalizing pallet  20 A;   securing the coil/load to the first load equalizing pallet using load binding straps  62 ; and   placing a second load equalizing pallet  20 B on the floor of the shipping container       

     Blocking  64  is also shown in  FIG. 11 , and it will be understood that this represents a partial attempt to secure the load equalizing pallets  20 A, 20 B against movement. 
     To complete the method:
         a second palletized coil is placed on the second load equalizing pallet  20 B and secured in place with load binding straps, in a manner identical to the placement and securement of the first; and   the pallets are secured against movement by blocking the bases thereof inside the shipping container using a framework of dimensional lumber constructed on the container floor.       

       FIGS. 12-14  are views showing the result of these completion steps, with  FIG. 13  being a view showing the blocking between the adjacent pallets  20 A/ 20 B and  FIG. 14  being a view showing the blocking  64  at the container doorway. 
       FIG. 15  shows an interim stage of an exemplary van trailer method, i.e. after the steps of:
         placing a first load equalizing pallet apparatus  20 A on the floor of the van trailer  87     placing a palletized coil  60  on the first load equalizing pallet  20 A; and   securing the load  60  to the first load equalizing pallet  20 A using load binding straps  62     placing a second load equalizing pallet  20 B on the floor of the trailer       

     Bracing  66  is also shown in  FIG. 15 , and it will be understood that this represents a partial attempt to secure the load equalizing pallets  20 A/ 20 B against movement. 
     To complete the van method (not shown):
         a second palletized coil is placed on the second load equalizing pallet  20 B and secured in place with load binding straps, in a manner identical to the placement and securement of the first; and   the pallets are secured against movement by operatively nailing the bracing to the floor of the van.       

     Turning now to  FIGS. 16-18  and the exemplary shipping apparatus  68  shown therein, this apparatus should be understood to include the load equalizing pallet apparatus  20  and a shelf apparatus  22 . 
     The shelf apparatus comprises a pair of standards  72  and a pair of deck structures  74 . 
     Each standard is a rigid frame having a pair of outer legs  76 , an inner leg  78 , a bottom rail  80  and a top rail  82  having four sockets  84  defined therein. 
     Each deck structure  74  includes a pair of parallel cross-beams  86  rigidly secured together by a pair of longitudinal braces  88 . At the end of each cross beam  86  is a pin  90 . 
     In use, as shown in  FIG. 16 , the standards  72  are positioned one on each side of the pallet apparatus  20  such that the outer legs  76  of the standards are fitted into outwardly-projecting lugs  44  of the pallet  20 . Thereafter, the deck structures  74  are lifted onto the standards, and the pins  90  are fitted into the socket  84  such that each of said one or more deck structures span between and are coupled to the pair of standards to space the standards apart. This thus creates a load-receiving surface  92 , defined by the upper surface of the deck structures, to receive skids  94  of relatively light-weight material. Prior to placement of the skids, spacer blocks  96  are wedged between the standards  72  and the wall of the container, to level and otherwise properly position the load-receiving surface. After the skids  92  have been placed, blocking  98  is wedged between the skids and the container walls, and between the skids and the front and rear legs, to avoid load shifting. 
     Although not shown, it will be appreciated that fork lift trucks will be used to position and place both the load-equalizing pallets and the loads, and that, depending upon loading conditions and loads, reinforcement of the floor surface with steel plates or the like may be desirable or necessary. 
     It will be appreciated that the foregoing provides significant advantage. For example, only:
         the present invention permits relatively heavy steel coils, along with relatively bulky, lightweight secondary loads, to be shipped in containers, van trailers or box trucks to points remote   the nature of the components permits (i) the originating shipper to maintain a relatively large quantity of the components in inventory in a relatively small space; and (ii) permits a relatively large number of the components to be return-shipped to the originating shipper in a container or the like   because of the relatively inexpensive nature of the load-equalizing base, and the removable nature of the shoes, it is possible at the destination of the coil/load for the wooden base to be separated from the shoes and recycled, thereby avoiding the need to return ship the wood, and the associated cost   the various components can be relatively quickly assembled and broken down, with commensurate impacts on productivity.       

     The invention also permits shipping of relatively heavy reels in containers, as shown in  FIGS. 19-21 . 
     For example, the invention can be used for the purpose of shipping four heavy reels in a 40′ container:
           FIG. 19A  is a top plan schematic view of a 40′ container  100  in which four of the load equalizing apparatus  20  are loaded and in operative receipt of reels  102 ;     FIG. 19B  is a side schematic view of the structure of  FIG. 19A ; and     FIG. 19C  is an end view of the structure of  FIG. 19A .       

     Details of the loading methodology are shown  FIGS. 21A and 21B . Herein, it will be seen that each reel  102  is supported against rolling by wood wedges  101  which are long enough to extend about 10″ beyond each side of the reel  102 ; against tipping by blocking  104 ; and generally by chain lashing  106 . An alternate loading methodology is shown in  FIGS. 22A and 22B , which includes similar wedges  101  and blocking  104 , but steel banding  108  in the place of chain lashing. The latter methodology is preferred in circumstances wherein the costs of return shipping the chain lashing would be relatively high. 
     As well, the invention can be used for the purpose of shipping five loaded reels in a 53′ container:
           FIG. 20A  is an end schematic view of a 53′ container  110  in which five of the load equalizing apparatus  20  are loaded and in operative receipt of reels  102 ;     FIG. 20B  is a top schematic view of the structure of  FIG. 20A ; and     FIG. 20C  is a side view of the structure of  FIG. 20A  but wherein one of the load equalizing apparatus is in the process of removal.       

     Whereas but a few exemplary embodiments and used are described and illustrated herein, various modifications can be made without departing from the spirit of the invention. Accordingly, the invention should be understood as limited only by the accompanying claims, purposively construed.