Abstract:
A case for moving flat screen displays (plasma lcd and led), interactive white boards, digital signage and the like, comprising: a base and a mating lid; said base and said mating lid forming a fully enclosed storage compartment when fitted together; said base and said mating lid shaped to form a case that has a small depth compared to its height and width to create a storage compartment that is suitably shaped to accommodate a flat shaped item in a vertical orientation; said base having lateral ends that are wider in relation to the middle to create a stable base for the case; said base further comprising a cradle assembly to hold the item to be transported in cushioned suspension above the bottom surface of said base.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of U.S. Provisional Patent Application No. 61/224,335, filed Jul. 9, 2009. All subject matter set forth in provisional application No. 61/224,335 is hereby incorporated by reference into the present application as if fully set forth herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    This invention relates to transport containers for safely moving flat screen display devices such as LCD, plasma, and LED flat display screens, interactive white boards, and like items that are large, flat shaped items which have sensitive surfaces that can easily be damaged if not well protected during transport from contact with surfaces inside the case. 
         [0004]    2. Description of the Related Art 
         [0005]    Flat screen display devices such as liquid crystal display (LCD), plasma, and LED displays, interactive white boards, and the like have created a need for specialized transport containers to move these large, expensive items without damaging them. The screen surfaces are susceptible to damage if they are bumped or rubbed. Thus, rental companies, moving companies, conference centers, sound and video contractors, and performance staging companies are all in need of a light weight, stable, reusable transport case that can fully protect these delicate, flat shaped devices during transport. 
         [0006]    U.S. Pat. No. 7,466,372 B2 to Kim discloses a transport case for the liquid crystal cells that are ultimately manufactured into a display, but this case is not designed to accommodate and protect a large end product display. 
         [0007]    U.S. Pat. No. 7,140,508 to Kuhn discloses a flat shaped wooden shipping case for valuables such as framed paintings. This wooden case has a shipping holder to secure the painting within the case, and further utilizes vacuum insulation panels to protect the contents from fire and extreme temperature changes. The shipping holder disclosed in this patent encloses the entire perimeter of the painting. This case is not suitable for moving delicate flat screen items because it is too heavy, it does not provide a means to keep the item oriented vertically up, and it does not have a means to protect packaging materials from rubbing against the delicate screen surface. 
         [0008]    U.S. published application 20080272136 entitled Transport Case For Transport Of High Value Heavy Transport Goods discloses a transport case designed to transport very heavy items, such as printers, that must be removed from the case with a lift truck. It features a sliding object carrier at the base of the case that can move the item closer to the side of the case where the lift truck is situated. The lid of this case also comprises the sides of the case when closed so that when the lid is removed, there are no sides in the way of the lift truck when the case is opened. This case is not useful for flat screen items because lift trucks are not necessary for flat screen items, and the moving companies and conference center industries do not wish to use lift trucks to move flat screen items. Further, it does not incorporate the novel shape that is ideal for stabilizing flat screen items in an upright orientation, and the design features that can protect a large screen area from being touched. 
       SUMMARY OF THE INVENTION 
       [0009]    It is an object of the present invention to achieve a transport case for moving large, delicate, valuable flat screen items that is lightweight so it is manageable, and shaped to accommodate large, flat screen items and keep them in their vertical, upright position throughout the moving process. 
         [0010]    It is further an object to achieve a case that protects the flat screen item from the impact of any bumps by suspending the item in shock absorbing cushion away from the rigid interior surfaces of the case. 
         [0011]    It is further an object to achieve a case that protects the delicate screen surface of the item to be moved from rubbing or contacting any cushioning, packaging, or assemblies designed to hold the item within the case. 
         [0012]    It is further an object to achieve a case that incorporates rollers at the base to further stabilize the case in an upright position and to provide for easy movement of the large case. 
         [0013]    It is further an object to incorporate useful handles to facilitate the lifting and moving of a large case and lid. 
         [0014]    It is further an object to incorporate lid securing straps. 
         [0015]    In one preferred embodiment, a transport case for moving large, flat screen devices includes a base and a mating lid. The lid is configured such that the lower portion slides over the corresponding top portion of the base to form a fully enclosed container. The base and lid are shaped such that the resultant case has a small depth compared to its height and width (i.e. a flat screen shape), to accommodate large, flat screen items. The case is wider at the lateral ends to provide a stable surface to keep the case in an upright orientation and prevent it from tipping over. The lower portion of the lid that overlaps with the top portion of the base at the widened lateral ends incorporates a horizontal shelf that rests on the corresponding top vertical edge of the base to hold the lid in suspension above the item to be transported. The wider base also serves to accommodate the end supports of a cradle system that keeps the item to be transported in cushioned suspension away from the interior sides of the case. The cradle system opening is adjustable to ensure that various sized items can be securely held within the case without any part of the cradle holding assembly touching the delicate flat screen area of the item to be transported. The case is made of lightweight plastic that is reinforced to ensure the sides do not collapse onto and touch the item inside without adding any appreciable weight to the case. Wheels, handles, and straps to secure the lid over the base can be added for additional convenience and security. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    There are shown in the drawings certain exemplary embodiments of the invention as presently preferred. It should be understood that the invention is not limited to the embodiments disclosed as examples, and is capable of variation within the scope of the appended claims. In the drawings, 
           [0017]      FIG. 1  is an exploded perspective view of an embodiment of the present invention with the lid separated from the base, 
           [0018]      FIG. 2  is a perspective view of an embodiment of the present invention with the lid closed over the base, 
           [0019]      FIG. 3  is an exploded perspective view of an embodiment of the present invention showing the cradle assembly of the base, 
           [0020]      FIG. 4  is an exploded perspective view of an embodiment of the present invention showing the reinforced channels of the base, and 
           [0021]      FIG. 5  is a cross sectional front view of an embodiment of the present invention with the lid closed over the base. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    Referring to  FIGS. 1-5 , flat display transport cases according to embodiments of the present invention are now described. 
         [0023]      FIG. 1  is an exploded view of an embodiment of the invention with the lid separated from the base. The case  1  comprises a base  2  and a mating lid  3 . The base  2  has a bottom  4 , an opening at the top  5 , and a plurality of sides  6  extending upward from the bottom  4 . The lid  3  comprises a top  7 , an opening at the bottom  8  (opening not visible), and a plurality of sides  9  extending downward from the top  7 . 
         [0024]    The base  2  and the lid  3  are cooperatively shaped, with the opening  8  at the bottom of the lid  3  having a larger perimeter than the opening  5  at the top of the base  2 , so that the lid  3  can slide over the base  2  in an overlapping fashion, creating a fully enclosed storage compartment inside.  FIG. 2  depicts an embodiment of the invention with the lid  3  closed over the base  2 . The lid  3  and the base  2  are cooperatively shaped such that the overlapping portion of the lid  10  slides over the corresponding top portion of the base  11  (hereinafter “nested portion of the base”), which is not visible in  FIG. 2  because it is nested under the overlapping portion of the lid  10 . 
         [0025]    The base  2  and lid  3  are sized and shaped to cooperatively form a case  1  that accommodates a large, flat item in a vertical orientation. Thus, in the top up orientation depicted in  FIG. 1  and  FIG. 2 , the resulting case has a relatively thin depth as compared to its height and width. 
         [0026]    Referring to  FIG. 1 , it can be seen that the depth of the base widens at both lateral ends  12  as compared to the middle  13 . The overlapping portion of the lid  10  correspondingly widens at the lateral ends. This unique shape provides a stable base to prevent the case  1  from tipping over on its side. This unique shape simultaneously creates a horizontal lid surface barrier  14  that prevents the lid  3  from resting on the top of the item to be transported. Thus, in the closed position, the lid  3  is prevented from resting on the top of the item to be transported, and instead, rests upon the vertical top edges of the base  35  that correspond to the horizontal lid surface barriers  14 . This unique shape also perfectly accommodates the cradle assembly that is installed into the interior bottom  4  of the base  2 , described further herein. 
         [0027]    The case  1  of the disclosed embodiments is fabricated of polyethylene plastic that is rotationally molded as a single piece, and is then divided into nested base  2  and overlapping lid  3  by cutting out a thin, transverse slice at the location that will become the mating edges of the base  2  and lid  3 . Rotational molding is a process known in the art for economically producing precision shaped plastic structures of uniform thickness. It produces molded plastic that is approximately 0.150 inches thick, resulting in a surprisingly light and manageable case given its size. Using a single mold as opposed to two molds results in less wasted plastic. 
         [0028]    Although thin molded plastic has the advantage of being light, durable, and low cost, it would not be ideal for fully protecting broad screen items such as large plasma displays without some reinforcement. The challenge is providing the reinforcement without appreciably increasing the overall weight of the case. Thus, in order to prevent the sides from collapsing in and possibly touching the delicate screen of the item inside, the inventors herein devised a way to reinforce the broad sides  17  of the front and back of the case (labeled on  FIG. 2  and  FIG. 4 ) without adding substantially to the weight of the case  1 . 
         [0029]    More specifically, in the disclosed embodiments, reinforcing channels  15  are molded into the base  2  and lid  3  as shown in  FIG. 1 . The channels  15  are designed to receive metal braces  16  (depicted in  FIG. 4 ) that are riveted to the interior of the channel, or attached therein by any suitable means.  FIG. 4  is an exploded view that depicts an advantageous arrangement of reinforcing channels  15  for the base  2 . This embodiment utilizes two channels  15  that wrap around the bottom  4  and receive the braces  16  as depicted. This advantageous arrangement holds the central portion of the broad sides of the base  17  rigidly away from the contents of the case. No bracing is utilized at the lateral ends  12  of the base  2  because the cradle assembly end supports  20  (discussed further herein) provide the needed reinforcement at the lateral ends  12 . 
         [0030]    Corresponding channels  15  are incorporated into the lid  3  as depicted in  FIG. 1  and  FIG. 2 . Since the height of the lid  3  is not as great as the height of the base  2 , it is not necessary to wrap the channels around the top of the lid  7  to prevent the middle sides  17  of the lid  3  from collapsing and touching the item within the case. Instead, the lid  3  of  FIG. 1  has an array of molded in ribs  18  to increase the rigidity of the top without adding the weight of metal braces. 
         [0031]    Aluminum is a useful brace material in that it is sufficiently rigid, yet light and resistant to corrosion. This novel process of utilizing the strategic placement of reinforcement channels only where needed, in combination with other case structures, allows the case to remain very light weight, yet rigid enough in critical locations to fully protect the contents from contact. 
         [0032]    Upon reading this disclosure, those skilled in the art may recognize other suitable materials and possible channel arrangements for utilizing lightweight materials in conjunction with bracing channels to practice the disclosed invention. The above disclosure is intended to fully disclose the invention, including preferred embodiments, and is not intended to limit the scope of the claims to the exact materials or channel layouts disclosed herein. The invention may be practiced with other suitable materials and may be practiced with or without reinforcing channels. 
         [0033]    The base  2  further comprises a cradle assembly to hold the item to be transported in cushioned suspension above the interior of the bottom of the base  4 .  FIG. 3  is an exploded view of the base  2  that depicts a cradle assembly in accordance with the present invention. The cradle assembly is comprised of two cushioned end supports  20 , and two middle cushions  21 . The end supports  20  are separately molded polyethylene plastic in the disclosed embodiment. They are comprised of a bottom  22 , and three sides  23 . The top  24  and the fourth vertical side  25  are left open to receive and hold the item to be transported. 
         [0034]    The end supports  20  are secured to the interior bottom and sides of the base  2  (not fully depicted) by rivets or any other suitable means. The interior bottom  4  of the base  2  may be formed with protrusions (not depicted) to guide the proper alignment of the end supports  20  onto the interior bottom  4  of the base  2  during assembly. To provide a fully cushioned cradle, the disclosed end supports  20  can be interiorly lined on all surfaces ( 22  and  23 ) with a type of molded foam known in the art as closed cell polyethylene foam  26 . The molded foam lining  26  can be permanently adhered to the end supports with a pressure sensitive adhesive that is known in the art to be suitable for this use. 
         [0035]    Additional strips of adhesive backed molded foam  27  can be adhered to the foam lining  26  to adjust the size of the end support opening (defined by the open top  24  and the open fourth vertical side  25 ). The exploded view of  FIG. 3  shows how wider strips  27   a  can be used at the lateral ends to shorten the depth of the end support opening, and narrower strips  27   b  can used to adjust the width of the end support opening at precisely selected locations to allow the foam  27   b  to touch only the frame of the item to be transported and not touch the delicate screen area. These additional strips of foam  27  can either be permanently attached, such as with pressure sensitive adhesive, or they can be removably attached, such as with Velcro, to allow custom adjustments to a single case  1  for a variety of flat screen items. 
         [0036]    The two middle cushions  21  can be fabricated of the same foam in the shape depicted in  FIG. 3 . They can be permanently adhered to the interior bottom  4  of the base  2 , spaced in a roughly equidistant manner between the two end supports  20 . The middle cushions  21  are shaped to support the bottom edge of the item to be transported, and to work in unison with the end supports  20  to support the item to be transported in cushioned suspension above the interior bottom  4  of the case.  FIG. 5  is a cross sectional view of a closed case that depicts the cradle assembly installed into the bottom of the base  4 . This embodiment also includes lid foam cushions  28  on the interior of the top  7  of the lid  3 . 
         [0037]    It can be seen from  FIG. 5  how the bottom of the item to be transported (item to be transported not depicted) would rest on horizontal foam surfaces  26  and  21  in suspension above the rigid interior bottom of the base  4 . The vertical sides  23  (see  FIG. 3 ) of the end supports  20  hold the corresponding vertical sides of the item to be transported firmly in place. The foam lining  26  of the vertical sides provides cushioning from impacts, and the custom foam strips  27  reduce the depth and width of the end support opening to snuggly hold the frame of the item to be transported without touching the delicate screen area. See also  FIG. 1  for a view of the tops of the end supports  20  with associated cushioning ( 26 ,  27   a,    27   b ). 
         [0038]    Those skilled in the art will recognize and appreciate that a cradle assembly in accordance with this invention can be fabricated of different materials and shapes. The detail provided above is intended to provide a full and complete disclosure including preferred embodiments, and is not intended to limit the scope of the claims to the specific cradle assembly embodiments disclosed above. 
         [0039]    To enhance the mobility of the case  1 , rolling mechanisms  29  (labeled in  FIG. 2 ) can be attached to the exterior bottom of the base  4  in any suitable fashion known in the art. The disclosed embodiments utilize four caster wheels  29  (three are visible), two at each lateral end. The casters  29  are bolted to the exterior bottom  4  of the base  2  in standard fashion. For enhanced directional control while moving the case  1 , the disclosed embodiments utilize two swiveling casters on one end (the forward end during movement), and two non-swiveling casters on the other end. 
         [0040]    The above arrangement of rolling mechanisms  29  are preferred for enhanced mobility and directional control, but those skilled in the art will recognize that any suitable number, orientation, and type of rolling mechanisms, or no rolling mechanisms at all, can be utilized to practice the invention. 
         [0041]    The  FIG. 2  embodiment includes two straps  30  to secure the lid  3  to the base  2 . The straps may be fabricated of heavy duty 1.5″ nylon web. They can be permanently secured to the front of the base at any suitable location (attachment point not shown), and wrap around the bottom of the base  4  being securely buckled at the top of the lid  7  (buckles not depicted). Camphered edges  31  as shown in  FIG. 2  can be utilized to prevent gaps between the straps  30  and the exterior bottom of the base  4 . In the disclosed embodiment, the straps  30  completely encircle the closed case  1 . It should be appreciated that the invention can be practiced without straps  30 , or with any variety of lid securing arrangements or devices known in the art. 
         [0042]    The case  1  of the present invention can be further equipped with a variety of handles. A useful arrangement is as depicted in  FIG. 1  and  FIG. 2 . The lid  3  is equipped with two lift bars  32 , one at each end, to facilitate lifting the lid  3  on and off the base  2 . The lift bars  32  can be fabricated with annodized aluminum tubing, or any other suitable handle type known in the art. A corresponding handle recess  33  is useful to allow plenty of room for a hand to grasp the bar  32 . The base  2  has two molded in end lift handles  34 , one on each end, to facilitate lifting the base  2  either alone, or with the lid  3  installed as needed. ( FIG. 5  depicts lift handles in cross sectional front view.) 
         [0043]    It will be appreciated that many varieties and arrangements of handles can be utilized within the scope of the invention, and that the invention is not limited to any particular handle arrangements. Handles are not necessary to practice the invention. 
         [0044]    The closed case embodiment of  FIG. 2  has the following approximate dimensions: 35 inches high, 54 inches wide, 16 inches deep at the widened depth, and 10 inches deep elsewhere. These dimensions are useful to accommodate the variety of sizes of large flat screen display devices that are prevalent in the market at the time of this application. 
         [0045]    The above disclosure is intended to fully disclose the invention including preferred embodiments. Modifications and variations of the present invention that would be obvious to a person of ordinary skill in the art are deemed to be within the scope of the present invention. For instance, those skilled in the art will appreciate that the invention can be practiced with a variety of lid and base arrangements, and the nested arrangement that incorporates the shelf to hold the lid above the item to be transported are not the only lid and base arrangements that can be used to practice the invention.