Patent Description:
In particular, the invention is intended for packaging, transporting and stacking oblong products such as rods, tubes and open profiles using reusable modules from a synthetic or a reusable and recyclable material or from a material that is sufficiently strong and lightweight to be handled manually and can be stored outside without rusting. It is known that such oblong products are currently typically packaged by fastening stacks of said products with heavy steel strapping, such that the underlying bundle is resistant to the pressure of the overlying bundles. Traditionally, lost packaging such as wooden planks, slats or beams are also often used which are typically used only once and cause a never ending waste flow when unpacking the transported goods. Moreover, the presence of dry wood also causes a fire hazard and the wood is unsuitable for storage in open air, where the wood can get wet and cause oxidation of the packaged objects.

Typically, such traditionally packaged goods are moved by means of a forklift truck, side loader or reach truck, whereby the forks of the transport vehicle often reach to beyond the packaged goods and thus regularly cause damage to other packaged goods for example. The lack of standardisation of such traditionally packaged bundles and packaging materials means that the packaged goods can often shift during transport, handling or storage, again resulting in damage to the packaged goods or to the surroundings.

<CIT> describes stackable modules for packaging oblong objects, each module consisting of two U-shaped welded steel profiles, connected by connection pieces of variable length to keep the two U-shaped profiles at a wanted distance from one another. The upstanding legs of the U-shaped profiles are equipped with a locking mechanism to lock their ends to a superposed module or to a lifting device such as a crane to lift the U-shaped profiles with their charge. The U-shaped profiles have slots in their bottom profiles allowing a fork of a forklift to lift a U-shaped profile. The U-shaped modules can be connected with male/female connections for their transport in an empty and decomposed state.

The purpose of the present invention is to provide a solution to the aforementioned and other disadvantages, by providing standardised packaging modules which can be ergonomically and manually handled and moreover are reusable and also <NUM>% recyclable.

To this end, the invention relates to stackable packaging modules for packaging oblong objects as defined in claims <NUM> and <NUM>. The invention also relates to a method for applying packaging modules as defined in claim <NUM>.

A first advantage of such stackable packaging modules is the increased safety when stacking and transporting the bundles of oblong objects.

Bundles of loads that are not completely flat at the top due to an incomplete row no longer pose a safety problem because the top is delimited on either side by the upright legs of the supporting packaging modules.

It also avoids the use of stowage aids made from inflammable materials such as wood, thus preventing not only fire and a risk of fire but also the creation of non-recoverable waste flows.

Another advantage is that the forks of the transport machines no longer come into contact with the load but only with the bottom packaging modules, such that the forks cannot damage the load.

An added advantage of the stackable modules is that they prevent suprajacent bundles from overloading the underlying bundles, which eliminates the need to fasten the bundles using strong steel straps. A much lighter fastening such as lashing straps or windings made from a light but strong material such as polyester can suffice to securely fasten every bundle to the stackable module on which the bundle is lying.

Another advantage of the stackable packaging modules is that they can be stacked to a higher safe height, because the modules support each other, which results in a smaller floor space for a given amount of stacked load.

Preferably, the lateral protrusions are mushroom-shaped protrusions or protrusions provided with an edge enabling the protrusion to interlock with an adjoining module.

Said protrusions allow several empty carrier modules to interlock with each other, such that they can be moved together by the forks of a forklift truck or another transport device without requiring a load-bearing pallet to this end.

Preferably the stackable packaging modules are made from a synthetic material or a material that is reusable and <NUM>% recyclable. The packaging modules made from a synthetic material or other non-oxidisable material offer the advantage that they can also be stored in open air and are not subject to water damage.

Preferably, the standard length of the horizontal bottom profile is <NUM> for all stackable packaging modules.

An advantage of said standard length is that it is wide enough to serve as a solid base for higher stacks without the risk of the load shifting or the stack falling over.

Another advantage of said standard length is that it ensures that the forks of a transport device such as a forklift truck do indeed support the complete bottom module, but do not protrude to beyond said module, such that damage to other nearby goods is avoided.

A major advantage of the standard length is that it opens the door to automation of the packaging, whereby the modules are always placed at the same distance from each other when packaging the oblong objects.

The height of the upright legs of the packaging modules is always the same in relation to each other but can vary in height depending on the number of heights one wants to produce.

An advantage of such different height levels is that they allow for a more accurate definition of the desired height of a stack and a maximum capacity utilisation of a lorry or a warehouse, without exceeding the maximum permitted weight.

The protrusions along both upright long sides of the horizontal bottom profile allow empty adjoining packaging modules to interlock with each other such that they, without a load-bearing pallet, can be handled, transported, or stacked.

The interlocking operation is provided by a mushroom-shaped end or another interlocking edge of the protrusions, which ensure that when the support under the bottom surface of a packaging module is removed, it still remains suspended between two adjacent modules when the protrusions make a connection with it.

The protrusions along both upright long sides of filled packaging modules protrude freely because the protrusions are also used to fasten the bundles of packaged objects to their load-bearing packaging module by fastening the bundles with straps made from synthetic material or lashing straps which are wrapped around the protrusions with an edge along both sides of the modules, with the purpose of retaining the relative position of the packaging module and the borne load bundle during the handing, transporting or stacking of the loaded packaging modules.

Preferably, the fixed centre distance between the vertical virtual middle sections across the load-bearing packaging modules is equal to <NUM> or <NUM> or a multiple thereof, with the purpose of being able to lift and move two or more packaging modules with their load by means of the forks of a forklift truck, reach truck or side loader.

The convex studs provided on the upperside of the upright legs of the stackable modules and which fit in the concave cavities provided to this end on the underside of an overlying module, automatically correct small position differences when stacking the modules and further prevent that the stacked packaging modules shift relative to each other during their handling, transport or storage.

Empty packaging modules can be slid against each other, such that the protrusions of the adjoining bottom profiles slide into the hollow recesses provided to this end of the first packaging module until a series of four or five or a multiple of four or five modules are against each other, after which the at least four or five modules can be lifted by two forks of a forklift truck or another transport device, whereby the modules not supported by a fork still remain fastened to each other by the interlocking operation of the protrusions and the at least four or five modules can be lifted self-supportingly without the need for a load-bearing pallet.

Said characteristic is important to easily recover the packaging modules after use or have them returned to their origin for reuse. Said recovery or return can be realised without additional repackaging materials and can be taken back via the same logistical flow as the delivery of the original load or by a pooling company specialised in this.

Obviously the load with the modules can also be moved by other means than by the forks of a forklift truck, such as traditional belts, girths or electric lifting magnets if the load allows it.

In a preferred variant of the packaging module according to the invention, the packaging module is provided with two collapsible upright legs, which can be manually raised or collapsed toward a vertical or horizontal position by rotating the leg and locking it in a vertical or a horizontal position.

Preferably the leg in question is raised or collapsed by sliding guide pins fixed to the upright leg into designated slots of a terminal shoe at each end of the horizontal bottom profile, to which the leg in question is or can be hingedly fastened.

A big advantage connected to said collapsible legs is that after use in raised position of the legs for the transport of a heavy load, the empty packaging modules can be transported in collapsed position of the legs, and use up a much smaller volume in the return transport for recovering the packaging modules.

In this variant the horizontal bottom profile is preferably <NUM> long, and the upright legs are of equal length, whereby said length can be <NUM> or <NUM>, said legs overlapping each other in collapsed position, or said length can be <NUM> or <NUM>, whereby the collapsed legs do not overlap in collapsed position.

In collapsed position, the empty packaging modules can be stacked on each other in stacks, after which up to five stacks are interlockingly slid against each other, and jointly lifted by one forklift truck without a supporting transport pallet.

It is handy hereby that the modules are perfectly symmetrical and do not have a front or back, such that the stacks of empty modules can be interlocked along both sides with an adjoining stack of empty modules.

All this means that the modules not only allow the packaging costs for said oblong objects to be lowered, but also for polluting packaging materials to be avoided, the safety to be increased and bringing both the automation of the packaging process itself, including the stacking of long products in the packaging modules and fastening the bundles to the modules with straps, and the automation of handling and transporting the bundles within reach. The standardisation inherent to said new method makes it simpler. Moreover, said modules allow transport and handling damage to be avoided.

With the intention of better showing the characteristics of the invention, a few preferred embodiments of stackable packaging modules according to the invention are described hereinafter by way of an example, without any limiting nature, with reference to the accompanying drawings, wherein:.

<FIG> shows a side view of a packaging module <NUM> according to the invention, consisting of a U-shaped profile <NUM> made from a reusable and recyclable material or a synthetic material or another material which is sufficiently strong and light, formed by a horizontal bottom profile <NUM> and two upright legs <NUM>, <NUM>, whereby the horizontal bottom profile <NUM> always has the same standard length L and the two upright legs in this case both have a higher height H and whereby the horizontal bottom profile <NUM> is provided along both upright long sides with protrusions <NUM>, <NUM>' and hollow recesses <NUM>, <NUM>' in which the protrusions of a horizontal bottom profile of an adjoining module fit and whereby the upright legs <NUM>, <NUM> on their upperside are provided with convex studs <NUM>, <NUM>' provided to this end which fit into concave cavities <NUM>, <NUM>' on the underside of the horizontal bottom profile <NUM> of an overlying module.

<FIG> shows a front view <NUM> of the packaging module <NUM> of <FIG>, whereby one upright leg <NUM> of the U-shaped profile <NUM> is shown with two, in this case mushroom-shaped protrusions <NUM>, <NUM>' and <NUM>, <NUM>', along both sides and whereby the horizontal bottom profile <NUM> is provided on the underside over the whole length with a slit-shaped recess <NUM> or shaft in which a fork of a forklift truck fits and whereby the upright legs <NUM>, <NUM> on their upperside are provided with one or two convex studs <NUM>, <NUM>' and <NUM>, <NUM>' which fit in concave cavities <NUM>, <NUM>' provided to this end on the underside of the horizontal bottom profile of an overlying module.

<FIG> shows a variant <NUM> of <FIG>, whereby in this case the upright legs <NUM>, <NUM> have a lower height h, but the horizontal bottom profile <NUM> always has the same standard length L.

<FIG> shows a top view <NUM> of two packaging modules <NUM>, <NUM>', whereby in this case the mushroom-shaped protrusions (<NUM>, <NUM>', <NUM> , <NUM>') of one module fit in the recesses provided to this end (<NUM>, <NUM>', <NUM>, <NUM>') in the second module and vice versa. The two modules are identical and always fit in each other, regardless of the side that is turned to the adjoining module.

<FIG> shows a load of oblong objects, packaged in one pair of packaging modules <NUM>, <NUM>' according to the invention, whereby in this case two modules with a height H are used to support the packaged load. The load is fastened by means of four straps (<NUM>, <NUM>, <NUM>, <NUM>) and fastened to the mushroom-shaped protrusions (<NUM>, <NUM>', <NUM>, <NUM>') along both sides of each packaging module (<NUM>, <NUM>') to securely fasten the load, in this case a bundle <NUM> of oblong objects, to the packaging modules.

The two modules are located at a fixed centre distance C between the vertical virtual middle sections <NUM>, <NUM>, of the load-bearing packaging modules, said centre distance being equal to <NUM> or <NUM>, with the purpose of being able to lift and move both packaging modules <NUM>, <NUM>' with their load by means of two forks of a forklift truck.

<FIG> shows a side view of a stack of several bundles <NUM> of oblong objects, in this case bundles of tubes, whereby each bundle has a different length, but every bundle is supported by symmetrically placed packaging modules <NUM> and all packaging modules are at the same centre distance C from each other. The two longest bundles are supported at the bottom by <NUM> towers <NUM>-<NUM> of two modules, the two medium-long bundles are stacked on them and are supported by six modules in the towers <NUM>-<NUM>, whereas the two shortest bundles were stacked at the top, supported by four packaging modules on the towers <NUM>-<NUM>.

<FIG> shows a top view of four empty packaging modules <NUM> that are slid against each other, such that the lateral protrusions <NUM>, <NUM>', <NUM>, <NUM>' are slid in the cavities <NUM>, <NUM>', <NUM>, <NUM>' provided to this end in the adjoining modules (not shown on this figure). The convex studs <NUM>, <NUM>, <NUM>', <NUM>' on the upperside of the upright legs <NUM>, <NUM> of each module <NUM> are shown as oblong shapes on the figure. The slots <NUM> at the bottom of every module <NUM>, in which a fork of a forklift truck fits, are also visible on the figure. The two most outer modules of the four modules are located at the fixed centre distance C between their vertical virtual middle sections <NUM>, <NUM> and therefore <NUM> from each other, with the purpose of lifting and moving the whole set of four empty packaging modules <NUM> together with the empty packaging modules <NUM> on top by means of two forks <NUM>, <NUM> of a forklift truck.

Examples having pointed studs in stead of convex studs are given in <FIG>, <FIG>.

<FIG> shows a side view of a stack <NUM> of empty collapsed packaging modules <NUM>, the bottom profile <NUM> of which has a length of <NUM> and the collapsed legs <NUM> a length of <NUM> and whereby the horizontal bottom profile <NUM> at both ends is provided with protrusions <NUM>, <NUM>' and hollow recesses <NUM>, <NUM>' in which the protrusions of a horizontal bottom profile <NUM> of an adjoining stack packaging modules can fit and whereby the collapsed legs <NUM> are provided on their upperside with pointed studs <NUM>, which fit in cavities <NUM> provided to this end on the underside of two feet <NUM> at the ends of the horizontal bottom profile <NUM> of a suprajacent packaging module, when the legs <NUM> are raised in a vertical position. The two collapsed legs <NUM> overlap each other and touch each other over almost their entire length.

Each horizontal bottom profile <NUM> is also provided at both ends with a shoe <NUM>, which is provided with slots in which the two guide pins <NUM>, <NUM> of a collapsible leg can be guided to raise or collapse them, and said shoe <NUM>, in collapsed position of the legs, offers space to the foot of a suprajacent bottom profile <NUM> of a collapsed packaging module stacked above, to keep said load in the desired location.

<FIG> shows a side view of a stack <NUM> of empty collapsed packaging modules <NUM>, as shown in <FIG>, but now with shorter collapsed legs <NUM> with a length of <NUM> which overlap and touch over a shorter distance, on the level of square lifting holes <NUM> in the collapsed legs <NUM> on the upperside of the collapsed legs <NUM>.

<FIG> shows a side view of a stack <NUM> of empty collapsed packaging modules <NUM>, but now with even shorter collapsed legs <NUM> with a length of <NUM> or <NUM> which no longer overlap or touch, such that the height of the shoes <NUM> at every empty collapsed packaging module <NUM> can be lower, and the stack <NUM> of empty packaging modules takes up even less space for the return transport.

Each horizontal bottom profile <NUM> is provided with two terminal shoes <NUM> at the ends of the horizontal bottom profile, whereby each leg <NUM> can be manually raised or collapsed in a vertical or horizontal position by rotating the leg and locking it in the vertical or the horizontal position by moving the guide pins <NUM>,<NUM> fixed to the rotating leg in slots of the shoe <NUM> provided to this end to which the leg is hingedly fastened.

<FIG> shows a packaging module <NUM> according to the invention in collapsed condition, said module being suitable for packaging very long objects and also called longtainer, and having the longest legs of <NUM>. On said figure the terminal feet <NUM> and shoes <NUM> on the horizontal bottom profile <NUM> are more visible as well as the guide pins <NUM>, <NUM> on every collapsed leg <NUM>, which by rotating the collapsed legs can be moved through the slots <NUM>, <NUM> provided to this end to hingedly bring the collapsed legs <NUM> to a vertical raised position, and locking them in the raised position. The square lifting holes <NUM> in the upright legs <NUM> of the packaging module <NUM> can be used to lift the module using a crane for example.

<FIG> shows a front view of a group <NUM> of five stacks <NUM> of empty and collapsed modules <NUM> slid against each other and thus interlocked because of the lateral protrusions <NUM>, <NUM>' in the horizontal bottom profiles <NUM> of a stack, which fit in recesses <NUM>, <NUM>' provided to this end in the horizontal bottom profiles <NUM> of an adjoining stack <NUM> of empty modules, with formation of a group of empty packaging modules in this case for collapsed legs <NUM> which overlap and require higher shoes <NUM> to be able to house the collapsed legs on top of each other. The whole group can now be lifted and transported by one forklift truck without requiring a transport pallet for support. By collapsing the legs, volume is saved in the transport of the empty modules to a location for reuse.

<FIG> also shows a front view of a group <NUM> of five stacks <NUM> of empty and collapsed modules <NUM> which are slid against each other, but now have shorter collapsed legs <NUM> that do not overlap and allow lower shoes <NUM>' to house the two collapsed legs next to each other. Said group thus saves even more space in the return transport of the empty modules for reuse.

<FIG> shows a front view of two pairs of packaging modules <NUM>, <NUM>' with raised legs <NUM> whereby between the raised legs <NUM> and the horizontal bottom profile <NUM> of each pair a load <NUM> is held, and whereby the second pair <NUM>' is stacked with its load <NUM>' on top of the first pair <NUM> with its load <NUM>. The top modules <NUM>' are kept in place by the pointed studs <NUM>, which fit in cavities <NUM>' provided to this end on the underside of the two feet <NUM>' at the ends of the horizontal bottom profile <NUM>' of a suprajacent packaging module <NUM>'. The load <NUM> is held in place by straps <NUM> which are wound around the load <NUM> and the protrusions <NUM>, <NUM>' of the horizontal bottom profiles <NUM>, <NUM>.

<FIG> also shows a front view of two pairs of packaging modules <NUM>, <NUM>' with raised legs <NUM> whereby between the now shorter raised legs <NUM> and the horizontal bottom profile <NUM>, <NUM>' of each pair of modules <NUM>, <NUM>', a load <NUM>, <NUM>' is held, and whereby the second pair of modules <NUM>' is stacked with its load <NUM>' on top of the first pair of modules <NUM> with its load <NUM>. The top modules are held in place by the pointed studs <NUM> provided on the upperside of the two raised legs <NUM>, which fit in cavities <NUM>' provided to this end on the underside of the two feet <NUM>' at the ends of the horizontal bottom profile <NUM>' of a suprajacent packaging module <NUM>'. The lower shoes <NUM>, <NUM>' of said packaging modules <NUM>, <NUM>' and the shorter raised legs <NUM>, <NUM>' make said packaging modules suitable for lower loads.

The operation of the packaging module <NUM> is very simple and as follows.

Each module has the same standard length and one of the available standard heights and can be manually handled and carried by a person because the weight is restricted (< <NUM>).

For packaging bundles of long objects, for example tubes, the bundles are packaged by placing each one, symmetrically or not, on a number of packaging modules <NUM>, which are each placed at a same centre distance (C) from each other by means of a forklift truck or other lifting device or simply manually. Even better is placing the packaging modules using a template or jig to place the modules at the correct distance from each other.

The bundles are fastened on each side of each packaging module by means of straps made from a light but strong material such as polyester, whereby the straps <NUM>-<NUM> or lashing straps are also guided around the mushroom-shaped or similar protrusions <NUM>, <NUM>', <NUM>, <NUM>' to securely connect the bundle <NUM> with each stackable module <NUM>, <NUM>' on which the bundle is lying.

The intention is to use at least one pair of modules <NUM>, <NUM>' or a multiple thereof, depending on the length of the load to be supported. There is no limit on the number of pairs of packaging modules that is applied to be able to cover the length of the load.

The weight of the top loads does not rest on the bottom loads, but on the underlying packaging modules, such that damage to the bottom loads is prevented. Said stacking method can be used for stacking goods in warehouses, but also in vessels or in lorries for example.

The standard length (for example <NUM>) of the packaging modules allows two such modules to be placed next to each other in the loading space of a lorry and stacked safely on the loading floor to utilise the useful loading volume of a lorry or container to maximum effect. The number of stacked bundles then depends on the chosen module height and the weight restrictions if any.

After the load has been delivered and the load has been unloaded, the used empty packaging modules can be recovered and recycled, for example, through the same logistics channel which took care of the delivery or by a pooling company contracted to this end. For this it suffices to place the four empty packaging modules next to each other with the lateral protrusions in the lateral cavities provided to this end in the adjoining packaging module and this up to <NUM>, <NUM>, <NUM> or more layers high.

A forklift truck can now lift the full length of the outer packaging modules with its forks, such that the intermediate modules are also lifted because the protrusions interlock with an edge into the adjacent modules. This method makes the use of transport pallets unnecessary to transport and recycle the used packaging modules.

The packaging modules are made from a <NUM>% recyclable synthetic material or other recyclable material and can be recovered after their lifetime. Preferably the packaging modules are made from remeltable aluminium. If they are made from a synthetic material they can be reused in the same or another application by grinding them into smaller granules.

The straps for fastening can also be made in a recyclable synthetic material such as polyester or another recyclable stainless material. The use of the packaging modules prevents the creation of residual waste from wood, for example, which benefits the fire safety of the packaging, or from steel, which can be subject to rust.

The standardisation of the dimensions of the packaging modules also allows the movements of the modules to be automated more than is the case now, not only for shipping loads, but also for recovering the used empty packaging modules for reuse and particularly for the packaging process itself.

In an alternative embodiment the two upright legs are hingedly or disassemblably fastened to the horizontal bottom profile, whereby the upright legs can be collapsed or disassembled when the packaging modules are empty, such that the empty modules are much more compact to transport them empty to a next load to be loaded.

If the two upright legs are hingedly fastened to the horizontal bottom profile, the two upright legs <NUM>, <NUM> of the collapsible packaging module are preferably fastened to the horizontal bottom profile <NUM> by means of two terminal shoes at the ends of the horizontal bottom profile, whereby each leg can be manually raised or collapsed in a vertical or horizontal position by rotating the leg and locking it in the vertical or the horizontal position by sliding the guide pins fixed to the upright leg in slots provided to this end in the shoe to which the leg is fastened.

In this alternative embodiment, the upright legs are collapsed after the load is removed, by manually rotating each collapsible leg from a vertical to a horizontal position, after which the collapsed packaging modules can be stacked on each other, whereby the horizontal bottom profile is provided at the bottom with a foot at both ends, said feet being fittingly slid in the space provided to this end in the shoes of the underlying collapsed module. The vertical stacks of empty packaging modules formed in this way can be slid horizontally against adjoining stacks to form a group of five stacks, whereby each stack interlocks with the adjoining stack by means of the lateral protrusions in the bottom profiles which interlock with the lateral cavities provided to this end in the bottom profiles of the adjoining stack.

Claim 1:
Stackable packaging modules (<NUM>) for packaging oblong objects (<NUM>), having a U-shaped profile (<NUM>), formed by a horizontal bottom profile (<NUM>) and two upright legs (<NUM>, <NUM>), whereby the horizontal bottom profile (<NUM>) always has a same standard length and the two upright legs (<NUM>, <NUM>) can have several heights, both however always being equally high, characterised in that the horizontal bottom profile along both upright long sides is provided with at least two protrusions (<NUM>, <NUM>', <NUM>, <NUM>') and at least two hollow recesses (<NUM>, <NUM>', <NUM>, <NUM>') in which the at least two protrusions and at least two recesses of a horizontal bottom profile of an adjoining module (<NUM>') fit, and that the U-shaped profile is made from a reusable and recyclable material or a synthetic material, and that the horizontal bottom profile (<NUM>) on the underside is provided over the whole length with a slit-shaped recess (<NUM>) in which a fork of a forklift truck, reach truck or side loader fits and in that the upright legs (<NUM>, <NUM>) are provided with convex studs (<NUM>, <NUM>', <NUM>, <NUM>') on their upperside which fit in concave cavities (<NUM>, <NUM>') provided to this end on the underside of the horizontal bottom profile (<NUM>) of an overlying module stacked on the bottom one.